Ford - Crown Victoria - Workshop Manual - 2000 - 2000

Factory Workshop Manual Make Ford Model Crown Victoria Engine and year V8-4.6L VIN W (2000) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 14 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 15 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 21 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0117 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0117 > Page 26 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 31 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 32 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 37 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 42 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 47 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 55 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 60 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 68 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 69 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 P0175 - P0179: Testing and Inspection P0175 For diagnosis of code P0175 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 74 P0175 - P0179: Testing and Inspection P0176 For diagnosis of code P0176 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 79 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 80 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 81 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 86 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 87 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 88 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 94 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 95 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 96 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 101 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 102 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 103 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 104 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 109 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 110 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis P0215 - P0219: Testing and Inspection For diagnosis of code P0217 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 118 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 119 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 125 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 126 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 127 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 128 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 133 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 134 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 135 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 136 P0305 - P0309: Testing and Inspection P0309 For diagnosis of code P0309 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to charts P0181 - P0325 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 147 P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 148 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 153 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 161 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 162 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 163 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 164 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 169 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 170 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 171 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 172 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 > Page 181 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 186 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 197 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 202 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 203 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 208 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 213 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of code P0500 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 219 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 220 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 221 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 222 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 223 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis P0505 - P0509: Testing and Inspection For diagnosis of code P0505 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 231 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to chart P0500 - P0813 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 237 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 238 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis P0605 - P0609: Testing and Inspection For diagnosis of code P0605 refer to chart P0500 - P0813 NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. (If replacement is necessary refer to Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM.) See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 242 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 248 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 253 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 254 P0705 - P0709: Testing and Inspection P0707 For diagnosis of code P0707 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 255 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 256 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 257 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 262 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 263 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 264 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission > Page 269 Note: "x" = any number 0 thru 9 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission > Page 270 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission > Page 271 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission > Page 272 P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission > Page 273 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0722 ( P 0722 ) For diagnosis of code P0722 refer to chart P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Manual Transmission > Page 274 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis P0725 - P0729: Testing and Inspection For diagnosis of code P072x refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 282 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 283 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 284 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 P0750 - P0754: Testing and Inspection P0750 For diagnosis of code P0750 refer to chart P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 289 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 290 P0750 - P0754: Testing and Inspection P0751 For diagnosis of code P0751 refer to chart P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 291 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 P0755 - P0759: Testing and Inspection P0755 For diagnosis of code P0755 refer to chart P0721-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 296 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 297 P0755 - P0759: Testing and Inspection P0756 For diagnosis of code P0756 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 298 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 P0780 - P0784: Testing and Inspection P0781 For diagnosis of code P0781 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 303 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 304 P0780 - P0784: Testing and Inspection P0782 For diagnosis of code P0782 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 305 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 306 P0780 - P0784: Testing and Inspection P0783 For diagnosis of code P0783 refer to chart P0756-P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 307 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P0815 - P1169 NOTE 1: DTC 1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continue as directed. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 317 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 323 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis P1110 - P1114: Testing and Inspection For diagnosis of code P1112 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 > Page 331 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 336 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 337 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 342 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 343 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 344 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 349 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 350 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 355 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 360 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 361 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 366 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 372 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1180 - P1460 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 373 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1180 - P1460 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 378 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 379 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 380 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 388 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 399 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 400 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 415 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 416 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 422 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 427 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 428 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 429 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 434 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems Refer to Pinpoint Test HX18. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests HX: Evaporative Emission (EVAP) Monitor and System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 439 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 444 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 445 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 446 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 447 P1460 - P1464: Testing and Inspection P1464 For diagnosis of code P1464 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis P1475 - P1479: Testing and Inspection For diagnosis of code P1479 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 462 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 463 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1461 - P1641 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 464 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 465 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 470 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 P1510 - P1514: Testing and Inspection P1512 For diagnosis of code P1512 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 > Page 475 P1510 - P1514: Testing and Inspection P1513 For diagnosis of code P1513 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 480 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 481 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 482 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 490 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to chart P1461 - P1641 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 508 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 509 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1461 - P1641 NOTE 18: DTC 1636 indicates the PCM has lost communication withthe Inductive Signature Chip. Replace the PCM (refer to Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 510 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 511 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1461 - P1641 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 512 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 520 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 526 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 527 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 528 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 529 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 Manual Transmission For diagnosis of code P1705 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission For diagnosis of code P1705 refer to chart Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 534 P500-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 535 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 536 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 P1710 - P1714: Testing and Inspection P1710 For diagnosis of code P1710 refer to chart P1636-P1718 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 541 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 542 P1710 - P1714: Testing and Inspection P1711 For diagnosis of code P1711 refer to chart P1636-P1718 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 543 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 544 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart P1636-P1718 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 545 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 546 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart P1636-P1718 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1710 > Page 547 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart P1636-P1718 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 552 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 553 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart P1636-P1718 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 554 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis P1725 - P1729: Testing and Inspection For diagnosis of code P1729 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 P1740 - P1744: Testing and Inspection P1740 For diagnosis of code P1740 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 562 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 563 P1740 - P1744: Testing and Inspection P1741 For diagnosis of code P1741 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 564 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 565 P1740 - P1744: Testing and Inspection P1742 For diagnosis of code P1742 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 566 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 567 P1740 - P1744: Testing and Inspection P1743 For diagnosis of code P1743 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 568 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 569 P1740 - P1744: Testing and Inspection P1744 For diagnosis of code P1744 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 570 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 575 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 576 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 577 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis P1750 - P1754: Testing and Inspection For diagnosis of code P1751 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis > Page 581 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1755 - P1759, ( P1756 P1757 P1758 1755 1756 1757 1758 1759 ) > System Information > System Diagnosis P1755 - P1759: Testing and Inspection For diagnosis of code P1756 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1755 - P1759, ( P1756 P1757 P1758 1755 1756 1757 1758 1759 ) > System Information > System Diagnosis > Page 585 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis P1760 - P1764: Testing and Inspection For diagnosis of code P1760 refer to chart P1740-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > Page 589 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1765 - P1769, ( P1766 P1767 P1768 1765 1766 1767 1768 1769 ) > System Information > System Diagnosis P1765 - P1769: Testing and Inspection For diagnosis of code P1767 refer to chart P1767-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 597 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 598 P1780 - P1784: Testing and Inspection P1783 For diagnosis of code P1783 refer to chart P1767-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis P1900 - P1904: Testing and Inspection For diagnosis of code P1900 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Control Module > Page 609 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Control Module > Page 612 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 613 Alarm Module: Service Precautions CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to a scan tool. This information needs to be downloaded in to the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network (Information Bus). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 614 Alarm Module: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Antitheft and Alarm Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 615 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to a scan tool. This information needs to be downloaded in to the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 616 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 scan tool into the new module. For additional information; refer to Module Communications Network (Information Bus). 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module Multifunction Electronic Control Modules: Locations Air Suspension Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module > Page 621 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module > Page 622 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 625 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 626 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 627 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 628 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 629 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 630 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 631 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 632 Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 633 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 634 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 635 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 636 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 637 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 638 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 639 Multifunction Electronic Control Modules: Connector Views Lighting Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 640 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 641 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 642 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 643 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 645 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ 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. For additional information, refer to Module Communications Network (Information Bus). ^ 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. For additional information, refer to Module Communications Network (Information Bus) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 646 Multifunction Electronic Control Modules: 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. 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). 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. The 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 input signals from various switches, sensors, and external modules. LCM subsystem functions 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 (DDM) via SCP for illuminated entry Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 647 Multifunction Electronic Control Modules: Testing and Inspection For air suspension concerns, refer to Electronic Level Control. See: Steering and Suspension/Suspension For Electronic Variable Orifice (EVO) steering concerns, refer to Steering. See: Steering and Suspension/Steering For warning chime concerns, refer to Instrument Panel, Gauges and Warning Indicators. See: Instrument Panel, Gauges and Warning Indicators For interior lighting concerns, refer to Courtesy Lamp. See: Lighting and Horns/Courtesy Lamp/Testing and Inspection For exterior lighting concerns, refer to the following sub-systems in Lighting and Horns: Backup Lamp. See: Lighting and Horns/Reversing Lamp/Testing and Inspection Brake Lamp. See: Lighting and Horns/Brake Lamp/Testing and Inspection Daytime Running Lamp. See: Lighting and Horns/Daytime Running Lamp/Testing and Inspection Headlamp/Autolamp. See: Lighting and Horns/Headlamp/Testing and Inspection Parking Lamp/Tail Lamp/License Lamp. See: Lighting and Horns/Parking Lamp/Testing and Inspection Public Safety Police Package Lighting. See: Lighting and Horns/Testing and Inspection Turn Signals/Hazard Lamps. See: Lighting and Horns/Turn Signals/Testing and Inspection For power window or defroster concerns, refer to Windows. See: Windows and Glass/Testing and Inspection For power lock and/or keyless entry concerns, refer to Keyless Entry. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 650 Multifunction Electronic Control Modules: Service and Repair Driver Door Module(DDM) 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. For additional information, refer to Module Communications Network (Information Bus). 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. For additional information, refer to Module Communications Network (Information Bus) 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 651 Multifunction Electronic Control Modules: Service and Repair Lighting Control (LCM) Module 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 into the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ 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 screws. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 652 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 New Generation STAR (NGS) Tester into the new module. For additional information; refer to Module Communications Network (Information Bus). 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions Keyless Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 656 Keyless Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 657 Keyless Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 658 Keyless Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions Keyless Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 663 Keyless Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 664 Keyless Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 665 Keyless Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 671 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 VIN W (2000)) 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 672 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 VIN W (2000)) 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 673 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 VIN W (2000)) 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 674 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 675 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 676 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 VIN W (2000)) 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 677 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 VIN W (2000)) 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 678 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 VIN W (2000)) 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 679 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 VIN W (2000)) 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 680 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 VIN W (2000)) 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 681 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 VIN W (2000)) 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 682 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 683 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 684 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 685 Power Door Lock Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 686 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 687 Power Door Lock Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 688 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 689 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 690 Power Door Lock Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 691 Power Door Lock Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 692 Power Door Lock Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 693 Power Door Lock Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 699 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 700 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 701 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 702 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 704 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 705 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 706 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 707 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 708 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 709 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 710 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Power Mirror Control Module: Electrical Diagrams For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 719 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 720 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 721 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 722 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 724 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 725 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 726 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 727 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 728 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 729 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 732 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 733 Power Seat Control Module: Electrical Diagrams For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-Lock Brake Control Module 1.8 - 2.8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 738 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 739 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 740 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 741 Electronic 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay > Page 747 Radiator Cooling Fan Motor Relay: Locations Cooling Fan Low Relay Diagram 11-03 Cooling Fan Low Relay is direct wired to the battery junction box. Wire color code is RD, RD/OR, DB and YE/Bk. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay > Page 748 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 749 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 750 Radiator Cooling Fan Motor Relay: Testing and Inspection COOLING FAN RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 760 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 761 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 762 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 763 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 765 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 766 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Blower Motor Relay: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 768 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 769 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 770 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 771 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C Lack of Cooling/Restricted Air Flow From Vents Compressor Clutch Relay: Customer Interest A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C Lack of Cooling/Restricted Air Flow From Vents > Page 782 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C Lack of Cooling/Restricted Air Flow From Vents > Page 783 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C Lack of Cooling/Restricted Air Flow From Vents > Page 784 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Compressor Clutch Relay: All Technical Service Bulletins A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 790 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 791 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 792 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C WOT Cut-Out Relay (Gasoline) View 151-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C WOT Cut-Out Relay (Gasoline) > Page 795 View 151-4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 796 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 797 Compressor Clutch Relay: Description and Operation Wide Open Throttle A/C Cut-Off The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 798 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 803 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 VIN W (2000)) 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 804 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Control Module HVAC: Locations Electronic Climate Control Module Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 807 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 808 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 809 Control Module HVAC: Locations Blower Motor Speed Control EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 810 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 813 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module Control Module HVAC: Description and Operation Electronic Climate Control Module Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 816 With the use of a microcontroller, the Electronic Automatic Temperature Control (EATC) module analyzes input from the following major sources: - temperature, function and blower selection (made by the vehicle occupants) - in-vehicle temperature sensor - ambient temperature sensor - sunload sensor - vehicle speed sensor - engine coolant temperature sensor Using these inputs, the microcontroller determines the correct conditions for the following outputs: - A/C clutch engagement - blower speed - air temperature blend door position - floor/panel door position - panel/defrost door position - air inlet duct door position Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 817 Part 1 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 818 Part 2 Of 2 System Response a If engine coolant temperature fails to reach 50°C (122°F) after 3-1/2 minutes of operation, the heater blower motor speed will increase and the windshield defroster door will shift from defrost position to floor position. b The A/C system is enabled by the EATC control assembly, but final control of the A/C compressor clutch is determined by the Powertrain Control Module (PCM) through the use of a normally open clutch control relay. The A/C clutch can be shut off (or kept off) for several seconds at engine start-up, during high engine speeds, during low engine idle conditions (approximately 200 rpm below idle specs) and when the engine coolant temperature sensor reading exceeds approximately 120°C (248°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 819 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Page 820 Control Module HVAC: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions Audible Warning Device Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions > Page 825 Audible Warning Device Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions > Page 826 Audible Warning Device Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions > Page 827 Audible Warning Device Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 DRL Module Bolt 3 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 832 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 833 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 834 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)Daytime Running Lamps or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 843 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 VIN W (2000)) 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 844 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 850 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 VIN W (2000)) 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 851 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Page 852 Exterior Lighting Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Exterior 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 855 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 856 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 857 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 858 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 860 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 861 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Exterior 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 863 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 864 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 865 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 867 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 869 Exterior Lighting Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Exterior Lighting Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 871 Exterior Lighting Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 872 Exterior Lighting Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 873 Exterior Lighting Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 874 Exterior Lighting Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch Hazard Flasher Relay: Locations Maltifunction Switch Hazard Flasher Relay is replaced by the Multifunction switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 879 View 151-6 Multifunction Switch Locations See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch Description and Operation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 880 Connector View See: Lighting and Horns/Diagrams Diagrams by Numbers, Diagram Set 90 Electrical Diagram Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 881 Hazard Flasher Relay: Locations Emergency Flasher Relays #1 and #2 (Police Option) Left hand rear of the luggage compartment, inside the emergency flasher relay block. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 882 Hazard Flasher Relay: Locations Rear Flasher Relay (Police Option) Center rear of the luggage compartment, on rear flasher relay. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 883 Hazard Flasher Relay: Diagrams EMERGENCY FLASHER RELAYS #1 and #2 (POLICE OPTION) Emergency Flasher Relays #1 and #2 (Police Option) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 884 Hazard Flasher Relay: Testing and Inspection EMERGENCY FLASHER RELAYS #1 and #2 (POLICE OPTION) Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 888 Horn Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Locations Illuminated Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 894 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 895 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 896 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 897 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 899 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 900 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Illuminated Entry 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 902 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 903 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 904 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 908 Illuminated Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 909 Illuminated Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 910 Illuminated Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 911 Illuminated Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 912 Illuminated Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 913 Illuminated Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Locations > Page 921 Mini ISO Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations POLICE POWER RELAY Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 925 Power Distribution Relay: Testing and Inspection POLICE POWER RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 930 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 931 Relay Box: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 932 Relay Box: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 933 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 936 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 937 Relay Box: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 944 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 VIN W (2000)) 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 945 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 VIN W (2000)) 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 > Page 946 Powertrain Control Module: Specifications Powertrain control module electrical connector bolt 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 947 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 948 Powertrain Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 949 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 950 Powertrain Control Module: Description and Operation The PCM carries out the following functions: ^ accepts input from various engine sensors to complete the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 951 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and remove the Powertrain Control Module (PCM) electrical connector. 3. Remove the PCM cover nuts. 4. Remove the PCM cover. 5. Remove the under dash sight cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 954 6. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 955 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 959 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 960 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 967 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 968 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 969 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 970 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 972 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 973 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 975 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 976 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 977 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 978 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 979 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 980 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 981 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 982 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 983 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 987 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 988 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 993 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 994 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 995 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 scan tool. 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 996 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. ^ 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 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 997 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 1002 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1010 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1011 Starter Relay: Description and Operation STARTING SYSTEM The starting system consists of the: - starter motor. - ignition switch. - digital transmission range (TR) sensor. - mini ISO relay. Starter Motor The starter motor: - is a permanent-magnet, gear reduction, 12V DC motor. - has an integral starter solenoid. Starter Relay 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. Normal Operation When the digital TR sensor recognizes that the vehicle is in either PARK or NEUTRAL and the ignition switch is placed in the START position, it sends a signal to the mini ISO relay that, in turn, sends a voltage signal to the starter solenoid, which will engage the starter motor to crank the engine at a speed fast enough to permit the engine to start. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1012 Starter Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1013 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Locations Air Suspension/Electronic Variable Orifice Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module > Page 1020 Steering Control Module: Locations Electronic Variable Orifice (EVO) Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 1021 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 1022 Steering Control 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1027 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1028 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1029 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Rear Air Suspension Control Module Screws 20-29 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1033 Suspension Control Module: Locations Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1034 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1035 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1036 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 charts. 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1037 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Locations Heated Glass Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions Heated Glass 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1044 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1050 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1051 Heated Glass 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1052 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 Heated Glass Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 Heated Glass Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 1060 Heated Glass Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 1061 Heated Glass Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 1062 Heated Glass Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 1063 Heated Glass Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1067 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1068 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Driver Door Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Driver Door Module > Page 1073 Power Window Control Module: Locations One Touch Window Down Module In the center of the left hand front door, near the master window/door lock control switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1076 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1077 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1078 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Power Window 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Power Window Control Module: Electrical Diagrams DRIVER DOOR MODULE For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1092 Power Window Control Module: Service Precautions DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1093 Power Window Control Module: Description and Operation DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1094 Power Window Control Module: Testing and Inspection DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1095 Power Window Control Module: Service and Repair DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions Power Window Relay: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Power Window Relay: 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > NHTSA00V138000 > Dec > 00 > Recall 00V138000: Wiper Control Module Replacement Wiper Control Module: Recalls Recall 00V138000: Wiper Control Module Replacement Vehicle Description: A windshield wiper control module may not be capable of carrying the current required during high load conditions on the wipers (i.e., ice, snow, or other debris). This condition could result in inoperative wipers with no advance warning. Dealers will inspect the wiper control modules and replace if necessary. Owner notification began May 19, 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 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). 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement Technical Service Bulletin # 00S09 Date: 000501 Recall - Wiper Control Module Replacement 00S09 SAFETY RECALL DEMONSTRATION/DELIVERY HOLD - Certain 2000 Model Year Crown Victoria and Grand Marquis - Windshield Wiper Control Module Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1127 Attachment I - Administrative Information OASIS OASIS will be activated for this recall Tuesday May 9, 2000. 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1128 ^ 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 cars are not authorized for this recall. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Seed Stocking of the wiper control modules will begin the week of May 15, 2000 and will continue for the next several weeks until 75% of each dealer's "Affected Unit Volume" has been shipped. The first seed stock shipment will be sent as an Interim Order. All other seed stock orders will be sent with your weekly Stock Order. After June 16, 2000, dealers should order parts through normal order processing channels. Service part orders for this wiper control module on vehicles not affected by this recall must be ordered through the Recall Hotline at 1-800-325-5621 until June 16, 2000. There are approximately 23,000 total vehicles involved in this recall. ORDER INFORMATION DOR/COR DOR/COR number 50160 identifies parts ordered for this campaign through the following: ^ Seed Stock Program ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1129 Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module location and replacement instructions. INSPECTION PROCEDURE The module must first be inspected for a green dot to determine if replacement is required. Modules that have a green dot have been updated at the assembly plant and do NOT require replacement. 1. Open the ashtray and look between the dash panel and the ashtray at the visible face of the wiper control module. 2. Inspect the module for a green dot (sticker). If necessary, shine a flashlight from under the dash panel to illuminate the module. If the module has a green dot, do not replace the module and return the vehicle to the customer. Replace the module if there is no green dot. MODULE REPLACEMENT PROCEDURE Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module replacement instructions. Bracket Transfer The module bracket must be transferred from the old module to the new module.The bracket is held in place by two round retaining buttons; depress the buttons simultaneously and slide the bracket off the old module. The bracket will lock into place automatically when it is slid onto the new module. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1130 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1131 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > NHTSA00V138000 > Dec > 00 > Recall 00V138000: Wiper Control Module Replacement Wiper Control Module: All Technical Service Bulletins Recall 00V138000: Wiper Control Module Replacement Vehicle Description: A windshield wiper control module may not be capable of carrying the current required during high load conditions on the wipers (i.e., ice, snow, or other debris). This condition could result in inoperative wipers with no advance warning. Dealers will inspect the wiper control modules and replace if necessary. Owner notification began May 19, 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 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). 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement Technical Service Bulletin # 00S09 Date: 000501 Recall - Wiper Control Module Replacement 00S09 SAFETY RECALL DEMONSTRATION/DELIVERY HOLD - Certain 2000 Model Year Crown Victoria and Grand Marquis - Windshield Wiper Control Module Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1141 Attachment I - Administrative Information OASIS OASIS will be activated for this recall Tuesday May 9, 2000. 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1142 ^ 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 cars are not authorized for this recall. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Seed Stocking of the wiper control modules will begin the week of May 15, 2000 and will continue for the next several weeks until 75% of each dealer's "Affected Unit Volume" has been shipped. The first seed stock shipment will be sent as an Interim Order. All other seed stock orders will be sent with your weekly Stock Order. After June 16, 2000, dealers should order parts through normal order processing channels. Service part orders for this wiper control module on vehicles not affected by this recall must be ordered through the Recall Hotline at 1-800-325-5621 until June 16, 2000. There are approximately 23,000 total vehicles involved in this recall. ORDER INFORMATION DOR/COR DOR/COR number 50160 identifies parts ordered for this campaign through the following: ^ Seed Stock Program ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1143 Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module location and replacement instructions. INSPECTION PROCEDURE The module must first be inspected for a green dot to determine if replacement is required. Modules that have a green dot have been updated at the assembly plant and do NOT require replacement. 1. Open the ashtray and look between the dash panel and the ashtray at the visible face of the wiper control module. 2. Inspect the module for a green dot (sticker). If necessary, shine a flashlight from under the dash panel to illuminate the module. If the module has a green dot, do not replace the module and return the vehicle to the customer. Replace the module if there is no green dot. MODULE REPLACEMENT PROCEDURE Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module replacement instructions. Bracket Transfer The module bracket must be transferred from the old module to the new module.The bracket is held in place by two round retaining buttons; depress the buttons simultaneously and slide the bracket off the old module. The bracket will lock into place automatically when it is slid onto the new module. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1144 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 1145 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 1146 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 1147 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 1148 Wiper Control Module: Service Precautions CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 1149 Wiper Control Module: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 1150 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 VIN W (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 1151 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 VIN W (2000)) 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 VIN W (2000)) 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1163 Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1164 Schematic Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 1165 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1169 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1170 Power Mirror Switch: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1171 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1172 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1173 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Control Switch Power Seat Switch: Diagrams Driver Seat Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Control Switch > Page 1178 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch Power Seat Switch: Testing and Inspection Driver Seat Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 1181 Terminals Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 1182 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 1183 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 1184 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 1185 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Regulator Control Switch Power Seat Switch: Service and Repair Seat Regulator Control Switch REMOVAL 1 Disconnect the battery. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Regulator Control Switch > Page 1188 Power Seat Switch: Service and Repair Front Seat Occupied Switch REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the seat. 3. Remove the seat track. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Description and Operation Power Trunk / Liftgate Lock Switch: Description and Operation Refer to Keyless Entry. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair Vacuum/Pressure Pump Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the seat. 3. Remove the cover. 4. Remove the screws. 5. Disconnect the connector. 6. Disconnect the vacuum tubes. NOTE: Mark the tubes before disconnecting. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair > Page 1195 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Brake Anti-Lock Sensor 36 - 53 in.lb Rear Brake Anti-Lock Sensor 14 - 19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1202 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1203 Wheel Speed Sensor: Service and Repair Sensor, 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1204 2 Remove the sensor. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 > Page 1210 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 1211 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 1212 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 1213 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1217 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1218 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1219 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations > Page 1223 Temperature Sensor (Gauge): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations > Page 1224 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 1229 Brake Switch (Cruise Control): Adjustments NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled. For additional information, refer to Brake Switch (Cruise Control). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 1230 Brake Switch (Cruise Control): Service and Repair 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 ml) or more to relearn its strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Page 1237 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. For additional information refer to Steering. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Manual A/C. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1249 Control Components 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1250 Ambient Temperature Sensor / Switch HVAC: 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1251 Ambient Temperature Sensor / Switch HVAC: 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 1255 Blower Motor Switch: Service and Repair Removal 1. Remove the control assembly. For additional information, refer to Control Assembly in this section. See: Heating and Air Conditioning/Control AssemblySee Service and Repair. 2. Note: The knob will drop off as the function selector is removed. Remove the function selector. 1. Depress the snap tabs. 2. Remove the function selector. 3. Note: The knob Will drop off as the temperature blend control switch is removed. Remove the temperature blend control switch. 1. Remove the screw. 2. Rotate and pull the temperature blend control switch. 4. Note: The knob Will drop off as the blower motor switch is removed. Remove the blower motor switch. 1. Depress the snap tabs. 2. Remove the blower motor switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Behind top center of Instrument Panel (I/P) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1259 Cabin Temperature Sensor / Switch: 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1260 Cabin Temperature Sensor / Switch: 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1261 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 1270 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 1276 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Refrigerant Pressure Sensor / Switch: Customer Interest A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 1285 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 1286 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 1287 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 1293 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 1294 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 1295 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 1298 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications Compressor Clutch Cycling Switch Closes at: 276-324 kPa Opens at: 152-193 kPa Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1299 Refrigerant Pressure Sensor / Switch: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1300 Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1301 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1302 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 1305 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling 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. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - (SCP) communication. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 1306 Air Conditioning High Pressure 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Compressor Cut-Off/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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 1309 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1313 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1314 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1315 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1316 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1325 Ambient Light Sensor: Service Precautions CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel to expose the connector without stretching the wiring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 1326 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Position 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Position Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 1338 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Position 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Position Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 1344 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 1345 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 1346 Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 1347 Brake Pedal Position 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 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Testing and Inspection Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Testing and Inspection > Page 1351 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1355 Hazard Warning Switch: Description and Operation Hazard Flasher Switch 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1356 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1357 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1358 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1359 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Removal Hazard Warning Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Removal > Page 1362 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Removal > Page 1363 Hazard Warning Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1367 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1368 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1369 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1370 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal Headlamp Dimmer Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal > Page 1373 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal > Page 1374 Headlamp Dimmer Switch: Service and Repair Installation 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1378 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1379 Main Light Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1380 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1381 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1382 Main Light Switch: Service and Repair REMOVAL 1. Remove the instrument panel cluster finish panel. For additional information, refer to Dash Board. 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 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair NOTE: The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Air Bag Systems. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1389 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1390 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1391 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1392 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Removal Turn Signal Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Removal > Page 1395 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Removal > Page 1396 Turn Signal Switch: Service and Repair Installation 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 VIN W (2000)) 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 VIN W (2000)) 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 > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1406 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1407 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1408 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1409 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1413 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1414 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1415 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 > Page 1422 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 1423 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 1424 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 1425 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1429 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1430 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 1433 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1434 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > 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 Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1438 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1439 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1440 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications Fuel Level Sensor: Specifications Fuel Level Sensor 4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications > Page 1444 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information Fuel Tank Pressure Sensor: Technician Safety Information WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information > Page 1453 Fuel Tank Pressure Sensor: Vehicle Damage Warnings CAUTION: ^ The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1454 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. The fuel tank pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. ^ is located in the fuel tank and is serviced as a separate item. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1455 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Partially drain and lower the fuel tank. For additional information, refer to Fuel Tank/Service and Repair. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair CAUTION: The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. 3. Push down and rotate the fuel tank pressure sensor counterclockwise to remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor Intake Air Temperature Sensor: Locations Ambient Air Temperature Sensor Center front of vehicle, on front of upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor > Page 1460 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1461 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1462 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1476 ^ 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1477 ^ 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1478 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1479 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1480 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1481 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1482 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1483 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1484 ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1485 ^ 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) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1486 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1487 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1488 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1489 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1490 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 1491 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) - Front 41 Nm Heated Oxygen Sensor (HO2S) - Rear 41 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 1492 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1510 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1511 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the powertrain control module used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the powertrain control module used to calculate catalytic converter integrity. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front Heated Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Service Tool(s) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the right side Heated Oxygen Sensor (HO2S) electrical connector. 3. Disconnect the left side HO2S electrical connector. 4. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 5. Using the special tool, remove the HO2S. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 1514 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 1515 Heated Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Service Tool(S) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 4. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9LA94-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Page 1516 Heated Oxygen Sensor: Tools and Equipment EGO Sensor Wrench EGO Sensor Wrench Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1523 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1527 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1528 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1532 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1533 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1534 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1535 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1536 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1542 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 VIN W (2000)) 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 1543 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 VIN W (2000)) 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 1544 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 VIN W (2000)) 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 1545 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1546 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1547 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 VIN W (2000)) 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 1548 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 VIN W (2000)) 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 1549 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 VIN W (2000)) 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 1550 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 VIN W (2000)) 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 1551 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 VIN W (2000)) 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 1552 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 VIN W (2000)) 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 1553 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1554 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1555 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1556 Vehicle Speed Sensor: Electrical Diagrams Diagram 64-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1557 Diagram 64-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1558 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1563 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1568 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1569 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1570 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 1571 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws 1.0 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Specifications > Page 1578 Inertia Fuel Shutoff Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Specifications > Page 1579 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Specifications > Page 1580 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Specifications > Page 1581 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Open the luggage compartment door. 2. Disconnect the connector from the Inertia Fuel Shutoff (IFS) switch. 3. Remove the retaining screws from the IFS switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1585 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1586 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1591 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1592 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1593 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1597 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1598 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 1601 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1602 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1608 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1609 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 VIN W (2000)) 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 1610 ^ 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 VIN W (2000)) 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 1611 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 VIN W (2000)) 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 1612 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 VIN W (2000)) 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 > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Installation Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 1615 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Installation 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. 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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 VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 1616 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. Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 1617 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. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 1618 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V050000 > Feb > 00 > Recall 00V050000: Airbag Crash Sensor Module Bolts Impact Sensor: Recalls Recall 00V050000: Airbag Crash Sensor Module Bolts Vehicle Description: Passenger vehicles. These vehicles may have been built with lower than the intended level of torque on the bolts that attach the airbag electronic crash sensor module to the vehicle. A loose module could result in a delayed air bag deployment in the event of a vehicle crash. Dealers will tighten the air bag electronic crash sensor attaching bolts. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA00V050000 > Feb > 00 > Recall 00V050000: Airbag Crash Sensor Module Bolts Impact Sensor: All Technical Service Bulletins Recall 00V050000: Airbag Crash Sensor Module Bolts Vehicle Description: Passenger vehicles. These vehicles may have been built with lower than the intended level of torque on the bolts that attach the airbag electronic crash sensor module to the vehicle. A loose module could result in a delayed air bag deployment in the event of a vehicle crash. Dealers will tighten the air bag electronic crash sensor attaching bolts. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 1646 Impact Sensor: Specifications Air Bag Sensor Bolts 12 Nm Crash Sensor Grounding Screw (N802455-S190) Weld Nut Repair Screw (8 mm) 12 Nm Grounding Screw (6 mm) (N806327-S190) 12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Crash Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Crash Sensor > Page 1649 Impact Sensor: Locations Right Primary Crash Sensor Right hand front of the vehicle, on the front of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1650 Impact Sensor: Description and Operation WARNING: THE AIR BAG ELECTRONIC 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 ARE~ OF THE ECS MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS contains two sensors which are integral to the ECS. The ECS is mounted on the RH A-pillar. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1651 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. ^ 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 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1652 ^ 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 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1659 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1660 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 VIN W (2000)) 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 1661 ^ 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 VIN W (2000)) 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 1662 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 VIN W (2000)) 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 1663 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Installation Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1666 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Installation 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. 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1667 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. Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1668 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. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1669 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1673 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 1683 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1684 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1685 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1686 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 1691 Ride Height Sensor: Description and Operation HEIGHT CONTROL SWITCH/SENSOR (LEVEL CONTROL) 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 1692 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 1697 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1698 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1699 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1700 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 VIN W (2000)) 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 SUSPENSION SWITCH 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 VIN W (2000)) 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 1704 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 1715 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1719 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Page 1720 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Lock Switch: > 06-21-19 > Oct > 06 > Customer Interest for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Lock Switch: > 06-21-19 > Oct > 06 > Customer Interest for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 1730 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 VIN W (2000)) 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 VIN W (2000)) 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 1734 Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1735 Transmission Mode Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1739 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1740 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1741 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1742 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1743 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1747 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1748 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 1758 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 1759 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 1760 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1763 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1764 Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1765 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1766 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1767 Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1768 Schematic Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1769 Power Window Switch: Testing and Inspection RR Window Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 1770 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1771 Power Window Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1776 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1777 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1778 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1779 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal Windshield Washer Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal > Page 1782 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal > Page 1783 Windshield Washer Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1787 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1788 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1789 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1790 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal Wiper Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 1793 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 1794 Wiper Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications Caster LH 5.5 +/- 0.75 deg RH 5.5 +/- 0.75 deg Total/Split 0.5 +/- 0.75 deg Camber LH -0.50 +/- 0.75 deg RH -0.50 +/- 0.75 deg Total/Split 0 +/- 0.75 deg Toe Total/Split -0.125 +/- 0.25 deg Toe @ curb ride height (positive value is toe-in, negative value is toe-out) Clear Vision -2.0 +/- 3 deg Negative value is counterclockwise Ride Height Base Front 1.2 +/- 0.5 in Rear 5.4 +/-0.3 in Ride Height Air Suspension Front 1.1 +/- 0.5 in Rear 5.2 +/- 0.3 in Ride Height Handling Package Front 1.0 +/- 0.5 in Rear 5.2 +/- 0.3 in Ride Height Police/NGV Front 1.0 +/- 0.5 in Rear 5.2 +/- 0.3 in Ball Joint Lateral Backlash Lower Ball Joint Max. 0.03937 in Upper Ball Joint Max 0.015 in Ball Joint End Play Lower Ball Joint Max 0.02 in Upper Ball Joint Max 0.02 in Vehicle Lean Front Wheel Opening Max 0.5 in Side to Side height differences Rear wheel Opening Max 0.5 in Camber and Caster Adjustment Nuts 129 ft lb Adjusting Sleeve Clamp Nuts 21 ft lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1801 Alignment: Description and Operation Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications provided will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1802 Alignment: Description and Operation Dogtracking 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1803 Alignment: Description and Operation 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). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1804 Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications provided will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Dogtracking Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1805 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. 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). General Information Wheel Alignment Angles ^ 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 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. 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 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 roadability problem, it is important to understand the difference between wander and poor groove feel. 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. Ride Height Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1806 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 scan tool. 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. Toe Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1807 Positive Toe (Toe In) Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel (3600) corrections to maintain a straight path down a level road. Wheel Track Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1810 Alignment: Service and Repair Toe Adjustment 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 1819 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 790 - 815 RPM Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 element. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1831 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1832 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1836 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 1845 Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1846 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1847 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1848 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1849 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1850 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1851 ^ 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1855 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt 6 Ribs Gasoline and natural gas 6K Poly V BeltTension is within specification if the tensioner is within the indicator markings Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1862 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by running the engine. 2. Inspect the drive belt for chunking, fraying and wear. 3. Cheek the drive belt for correct routing. The accessory drive: has a single serpentine drive belt. - has an automatic drive belt tensioner. - does not require adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1865 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1866 Drive Belt: Component Tests and General Diagnostics Belt Tension Note: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Belt Tensioner Check the automatic drive belt tensioner: 1. With the engine off, check for correct drive belt routing. Correct as necessary. 2. Rotate the drive belt tensioner and check for a binding or seized condition. Install new components as necessary. Drive Belt Cracking/Chunking/Wear V-Ribbed Serpentine Drive Belt with Cracks Across Ribs. V-Ribbed With Chunks of Rib Missing Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1867 Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of the drive belt. With the engine running, check drive belt tucking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. - Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the drive belt tracking. - Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an incorrectly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: If the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. - If the A/C OFF equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. - If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water. A new drive belt does not have to be installed if no apparent damage has occurred. - The drive belt tensioner arm should rotate freely without binding. - If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, install a new drive belt. - If the drive belt tensioner is worn or damaged. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1868 Drive Belt: Service and Repair Removal and Installation 1. Rotate the tensioner clockwise and remove the drive belt. 2. To install, reverse the removal procedure. Refer to Component Locations for drive belt routing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 element. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, and transmission cooler tubes must be thoroughly flushed to remove any dirt and the Oil-To-Air (OTA) must be replaced. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. The oil-to-air cooler must he 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 failure 2 When used under continuous or server conditions, the transmission and torque converter should be drained and refilled with fluid as specified. + Normal Maintenance Change fluid at 48,000 km (30,000 miles). + Sever Duty/Major Overhaul Change fluid at 48,00U km (30,000 miles). 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. 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. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1880 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 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. Installation 1. Note: A new torque converter drain plug must be used. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1881 Install the torque converter drain plug. 2. Install torque converter housing plug. 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1882 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. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use Motorcraft MERCON (R) V Automatic Transmission Fluid XT-S-QM or equivalent meeting Ford specification MERCON (R) V. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1887 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1888 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water bypass tube stud 15 - 22 ft.lb Water outlet adapter 18 ft.lb Water outlet connection bolts 18 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 1901 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 VIN W (2000)) 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 1902 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 VIN W (2000)) 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 VIN W (2000)) 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 1908 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 VIN W (2000)) 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 1909 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1910 Heating And Ventilation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1911 Heater Hose: Service and Repair REMOVAL 1. Drain the radiator. For additional information, refer to Cooling System. 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Peanut Fitting Nut 7 - 9 Nm Peanut Fitting Retaining Nut 7 - 9 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1915 Hose/Line 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 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 VIN W (2000)) 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. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. For additional information refer to the spring lock couplings disconnect and connect procedure. See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1918 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1919 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. For additional information refer to the spring lock couplings disconnect and connect procedure. See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1920 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1921 Hose/Line HVAC: Service and Repair Condenser to Evaporator Line REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Disconnect the condenser to evaporator tube from the A/C evaporator core. For additional information refer to the spring lock couplings disconnect and connect general procedure. See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1922 Hose/Line HVAC: Service and Repair Evaporator to Compressor Suction Line REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. For additional information, refer to the spring lock couplings disconnect and connect procedure. See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1923 6. Disconnect and remove the evaporator to compressor suction line from the A/C manifold and tube assembly. For additional information, refer to the spring lock couplings disconnect and connect procedure. See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1924 Spring Lock Coupling Disconnect Tool Set Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Removal Power Steering Line/Hose: Service and Repair Removal Removal 1. Refer to the System View illustration for the hose routing and retention points. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Removal > Page 1929 Power Steering Line/Hose: Service and Repair Installation Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1930 Power Steering Line/Hose: Tools and Equipment Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid Type ................................................................................................................................. ......................................... High Performance DOT 3 Ford Specifications .............................................................................................................................. ....................................................... ESA-M6C25-A Brake Fluid Type ................................................................................................................................. ......................................... High Performance DOT 4 Ford Specifications .............................................................................................................................. ............................................... SAE-J-1704-DOT 4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1935 Brake Fluid: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6A7-19542-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-J1704-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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1940 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Fluid Capacity 15 L Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1943 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ........................................................................ 13.1 L Note: Approximately Dry Fill Capacity Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1948 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1949 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, and transmission cooler tubes must be thoroughly flushed to remove any dirt and the Oil-To-Air (OTA) must be replaced. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. The oil-to-air cooler must he 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 failure 2 When used under continuous or server conditions, the transmission and torque converter should be drained and refilled with fluid as specified. + Normal Maintenance Change fluid at 48,000 km (30,000 miles). + Severe Duty/Major Overhaul Change fluid at 48,000 km (30,000 miles). 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. 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. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1950 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 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. Installation 1. Note: A new torque converter drain plug must be used. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1951 Install the torque converter drain plug. 2. Install torque converter housing plug. 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1952 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. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use Motorcraft MERCON (R) V Automatic Transmission Fluid XT-S-QM or equivalent meeting Ford specification MERCON (R) V. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ....................................................................... 3.75 pt Additive Friction Modifier ................................. ............................................................................................................................................................. 4 oz Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1957 Fluid - Differential: Fluid Type Specifications Differential Fluid Type 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1962 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1963 ^ 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1964 ^ 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1967 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................... SAE 5W-20 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1972 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1973 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1978 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1979 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1980 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1981 ^ 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Ford Designation Specification R134a Refrigerant YN-19 WSH-M17B19-A System Capacity 38 oz (US) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1984 Refrigerant: Fluid Type Specifications R-134a Refrigerant Ford Part Number................................................................................................................................. ...................................................Motorcraft YN-19 Ford Specification................................................................................................................................. ....................................................WSH-M17B19-A Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1985 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1986 Fax: 215-541-4635 http://www.macsw.org/ Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1987 Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure SPECIAL SERVICE TOOL(S) 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing. See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/Identifying Refrigerants 2. Connect the R-134a A/C Refrigerant Center to the low- and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. See: Heating and Air Conditioning/Service and Repair/Manifold Gauge Set Connection 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the refrigerant center has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the refrigerant center hose(s). 6. If the system pressure rises, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repair operations, then evacuate and recharge the A/C system. For additional information, refer to Evacuation and Charging. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Ford Designation Specification Motorcraft (R) Part # PAG Refrigerant Compressor Oil YN-12-C WSH-M1C231-B F7AZ-19589-DA System Capacity 207 mL Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1992 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) Ford Part Number................................................................................................................................. ................F7AZ-19589-DA (Motorcraft YN-12-C) Ford Specification................................................................................................................................. ...................................................WSH-M1C231-B Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1993 Refrigerant Oil: Service and Repair Refrigerant Oil Addition CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting the oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: New A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 0.5 in (12.5 mm) holes in the suction accumulator/drier cylinder and drain the oil into a calibrated Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1994 container. Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice - installation of a new A/C compressor pressure relief valve - installation of a new refrigerant line - repair of an O-ring seal leak - repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch, the A/C pressure cut-off switch and the A/C pressure transducer do not require additional oil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Front Disc Brake Caliper Bleeder Screw 9 - 13 ft.lb Front Master Cylinder Brake Tube 17 - 20 ft.lb Rear Bleeder Screw 12 - 18 ft.lb Rear Master Cylinder Brake Tube 11 - 14 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 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. Refer to Specifications. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2000 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Hush 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 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 scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the scan tool 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2001 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2002 Brake Bleeding: Service and Repair Brake System 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2003 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) 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. 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. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2004 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 scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the scan tool instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2005 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2006 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. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE J1704-DOT 4. 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. 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2007 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2012 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2013 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2014 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2015 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2016 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2022 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2023 Fuse: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2035 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2042 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2043 Fuse: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2048 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2049 Fuse Block: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2066 Fuse Block: Connector Views Central Junction Box C120: Only component connectors with 5 pins or more and in-line connectors with 6 pins or more are illustrated. Battery Junction Box (BJB) C120: Only component connectors with 5 pins or more and in-line connectors with 6 pins or more are illustrated. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2069 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2070 Fuse Block: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2075 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2076 Relay Box: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2077 Relay Box: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2078 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2081 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2082 Relay Box: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 2087 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Suspension Warning Indicator > Component Information > Description and Operation > Page 2097 Suspension Warning Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2107 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 VIN W (2000)) 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 2108 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 VIN W (2000)) 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 2109 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 VIN W (2000)) 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 2110 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 VIN W (2000)) 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 2111 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 VIN W (2000)) 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 2112 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2113 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2119 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 VIN W (2000)) 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 2120 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 VIN W (2000)) 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 2121 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 VIN W (2000)) 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 2122 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 VIN W (2000)) 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 2123 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 VIN W (2000)) 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 2124 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2125 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2126 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. ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2127 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2128 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2133 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2134 Tires: 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2135 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2136 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2137 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2138 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2139 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2140 Tires: Technical Service Bulletins Suspension - Repeated Tire Balancing Issues Article No. 00-26-7 12/25/00 ^ SUSPENSION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY - PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ WHEELS - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ VIBRATION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 FORD: 2000 CROWN VICTORIA This article is being republished in its entirety to update the build date coverage and Service Procedure. ISSUE Some 2000 model year Police Interceptors produced from 1/1/2000 through 8/14/2000 may have repeat issues with tire balance. This may be caused by tire slippage on the rim. ACTION Check for tire slippage on the rim using the following Service Procedure and if necessary, refer the customer to a Goodyear Service Center for tire service. SERVICE PROCEDURE Use the following procedure to test for tire slippage on the wheel. 1. Mark the tire and wheel for a reference location. 2. Conduct three (3) 80-0 km/h (50-0 mph) full stops with 1 kilometer (1 mile) cool down in between each run. 3. Inspect for slippage between the tire and wheel at the reference location. If no tire slippage is evident, balance the tires following the 2000 Crown Victoria Workshop Manual procedures. If tire slippage is evident, refer the customer to their local Goodyear Service Center for service. Goodyear has issued a Product Service Bulletin (PSB # 2000-48) which identifies the procedures to use to correct the issue. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-23-7 WARRANTY STATUS: Eligible Under The Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 306000, 703000, 703300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2141 Tires: Specifications Wheels and Tires Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2142 Tires: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias or bias-belted, on the same vehicle except in emergencies (temporary spare usage). Vehicle handleing can be seriously affected and can result in loss of control. Factory installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 VIN W (2000)) 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 VIN W (2000)) 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 2160 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 VIN W (2000)) 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 VIN W (2000)) 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 2165 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2166 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2167 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2168 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 VIN W (2000)) 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 2169 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-26-7 > Dec > 00 > Suspension - Repeated Tire Balancing Issues Wheels: All Technical Service Bulletins Suspension - Repeated Tire Balancing Issues Article No. 00-26-7 12/25/00 ^ SUSPENSION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY - PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ WHEELS - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ VIBRATION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 FORD: 2000 CROWN VICTORIA This article is being republished in its entirety to update the build date coverage and Service Procedure. ISSUE Some 2000 model year Police Interceptors produced from 1/1/2000 through 8/14/2000 may have repeat issues with tire balance. This may be caused by tire slippage on the rim. ACTION Check for tire slippage on the rim using the following Service Procedure and if necessary, refer the customer to a Goodyear Service Center for tire service. SERVICE PROCEDURE Use the following procedure to test for tire slippage on the wheel. 1. Mark the tire and wheel for a reference location. 2. Conduct three (3) 80-0 km/h (50-0 mph) full stops with 1 kilometer (1 mile) cool down in between each run. 3. Inspect for slippage between the tire and wheel at the reference location. If no tire slippage is evident, balance the tires following the 2000 Crown Victoria Workshop Manual procedures. If tire slippage is evident, refer the customer to their local Goodyear Service Center for service. Goodyear has issued a Product Service Bulletin (PSB # 2000-48) which identifies the procedures to use to correct the issue. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-23-7 WARRANTY STATUS: Eligible Under The Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 306000, 703000, 703300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2179 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 VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2184 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2185 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2186 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2187 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 VIN W (2000)) 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 > Page 2188 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-26-7 > Dec > 00 > Suspension - Repeated Tire Balancing Issues Wheels: All Technical Service Bulletins Suspension - Repeated Tire Balancing Issues Article No. 00-26-7 12/25/00 ^ SUSPENSION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY - PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ WHEELS - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ VIBRATION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 FORD: 2000 CROWN VICTORIA This article is being republished in its entirety to update the build date coverage and Service Procedure. ISSUE Some 2000 model year Police Interceptors produced from 1/1/2000 through 8/14/2000 may have repeat issues with tire balance. This may be caused by tire slippage on the rim. ACTION Check for tire slippage on the rim using the following Service Procedure and if necessary, refer the customer to a Goodyear Service Center for tire service. SERVICE PROCEDURE Use the following procedure to test for tire slippage on the wheel. 1. Mark the tire and wheel for a reference location. 2. Conduct three (3) 80-0 km/h (50-0 mph) full stops with 1 kilometer (1 mile) cool down in between each run. 3. Inspect for slippage between the tire and wheel at the reference location. If no tire slippage is evident, balance the tires following the 2000 Crown Victoria Workshop Manual procedures. If tire slippage is evident, refer the customer to their local Goodyear Service Center for service. Goodyear has issued a Product Service Bulletin (PSB # 2000-48) which identifies the procedures to use to correct the issue. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-23-7 WARRANTY STATUS: Eligible Under The Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 306000, 703000, 703300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2193 Wheels: Specifications Wheels and Tires Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire 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 beatings. 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 puffer 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2196 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2197 Wheels: Service and Repair Wheel Leaks WARNING: 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 installation of a new wheel. 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 a new wheel. 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-M14PI0-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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Page 2198 Wheels: Tools and Equipment Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 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. 2. Spin the tire by hand to check the wheel bearings for roughness. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 2204 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 2205 Wheel Bearing: Testing and Inspection Wheel Bearing 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 2206 Wheel Bearing: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 2207 2. Using the special tool, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tool, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer 221 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nuts 85-105 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front 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. 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2217 Wheel Fastener: Service and Repair Rear Removal Vehicles Equipped With Air Suspension 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. All Vehicles 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. All Vehicles 1. Insert a new lug bolt in the hole in the axle flange, making sure serrations are aligned with those in the flange. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2218 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. Vehicles Equipped With Air Suspension 8. Turn the air suspension service switch on. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 2219 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2228 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2229 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2230 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2231 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2232 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2233 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 2234 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2240 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 VIN W (2000)) 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 2241 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 VIN W (2000)) 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 2242 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 VIN W (2000)) 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 2243 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 VIN W (2000)) 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 2244 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 VIN W (2000)) 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 2245 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2246 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2247 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. ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2248 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 VIN W (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2249 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2255 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 71-107 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 2260 Camshaft Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt 81 - 95 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 2265 Camshaft Gear/Sprocket: Specifications Crankshaft Sprocket Bolt 81-95 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe lift Exhaust LH 0.259676 in Exhaust RH 0.2592713 in Intake 0.2590847 in allowable lift loss 0 in Valve lift at zero lash intake 0.4724409 in exhaust 0.4724409 in Camshaft end play 0.001062989 - 0.007480292 in Camshaft end play service limit 0.007480292 in Camshaft journal to bearing clearance 0.002992117-0.000984249 in Clearance service limit-journal diameters 1.061493 - 1.060469 in Clearance service limit journal inside diameter (cap assembled) 1.063461-1.062477 in Camshaft bearing cap bolts Refer to Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2269 Camshaft: Service and Repair Removal 1. Remove the timing chain. 2. 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. 3. Remove the camshaft sprocket and spacer. 1 Remove the bolt. 2 Remove the camshaft sprocket and spacer. 4. Remove the 13 camshaft bearing cap bolts. 5. Remove the camshaft bearing cap ladders. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2270 6. Remove the camshaft from the cylinder head. Installation 1. Lubricate the camshaft journals. - Use Super Premium SAE 5W-30 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-M2C153-G. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2271 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2272 7. Install the roller follower. 8. Install the timing chains. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 0.6294488 - 0.6299213 in Lash adjuster-clearance to bore 0.0007086614 - 0.00271535 in Lash adjuster-service limit 0.0006299213 in Lash adjuster-hydraulic leakdown rate 5-25 sec Lash adjuster-collapsed Lash adjuster gap desired 0.01771654 - 0.03346457 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2276 Lifter / Lash Adjuster: Service and Repair 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2280 Rocker Arm Assembly: Service and Repair Special Tools 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. 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2281 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair Connecting Rod Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Bolt CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. Note: The connecting rod caps are of the cracked design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly. Position the lower bearing and connecting rod, and install the new bolts loosely. Tighten the bolts in two stages, using the sequence shown. Stage 1: Tighten to 40 - 45 Nm (30 - 33 ft. lbs.). Stage 2: Rotate an additional 90 - 120 degrees. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2290 Connecting Rod: Specifications Big end journal inside diameter with assembled liners 2.238819 - 2.239606 in Rod bearing-to-journal clearance 0.002598425 - 0.0009448819 in Pin bore diameter (rod) 0.867084 - 0.8666116 in Rod length (centerline bore-to-bore) 5.933071 in Alignment bore-to-bore max. twist 0.001968498 in Alignment bore-to-bore max. bend 0.001496058 in Side play (as assembled to crank) Standard play 0.0005905512-0.01771654 in Max. play 0.01968504 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2291 Connecting Rod: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Journal to Main Bearing Clearance 0.66-0.024 mm Main Bearing Cap Bolts ---- Refer to the Engine; Service and Repair; Assembly for tightening specifications and sequences. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2298 Crankshaft Main Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications Crankshaft Seal Retainer: Specifications Rear main seal retainer plate 89 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main bearing journal diameter 2.656803 - 2.65759 in Main bearing bore diameter 2.850394 - 2.851339 in Connecting rod journal diameter 2.086726 - 2.085939 in Connecting rod journal diameter: maximum-out-of-round 0.00029574798 in Connecting rod journal diameter: maximum taper (straightness) 0.0001574798 in Crankshaft end play 0.01185039 - 0.00511811 in Main bearing journal diameter: maximum-out-of-round 0.0002952747 in between cross sections Main bearing journal diameter: maximum taper (straightness) 0.0001574798 in Runout: FIM of center journals when located on front and rear journal 0.001968498 in 3 places Crankshaft journal-to-main bearing clearance 0.002598425 - 0.000944879 in Crankshaft Main Bearing Caps Refer to Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2305 Crankshaft: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2309 Engine Block Heater: Service and Repair Removal and Installation 1. Drain the cooling system. 2. Raise the vehicle. 3. Disconnect the block heater power cable from the block heater. 4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Remove the block heater. 5. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or damage to the cable may occur. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Step 1 66 ft.lb Step 2 Loosen the bolt Step 3 34-39 ft.lb Step 4 Additional 85-90 degrees Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2313 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2314 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 WSE-M4G323-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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston-to-bore clearance mm @ 43 mm (1.72 in) from top -0.0001968504 - 0.000984252 in 10:1 ENGINES (NGV) Ring groove width, top 0.0484252 - 0.0492126 in Ring groove width, intermediate 0.05984252 - 0.06062992 in Ring groove width, oil control 0.1192913 - 0.1202756 in 9:1 ENGINES (GASOLINE) Ring groove width, top 0.05984252 - 0.06062992 in Ring groove width, intermediate 0.05984252 - 0.06062992 in Ring groove width, oil control 0.1192913 - 0.1202756 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2318 Piston: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications 10:1 ENGINES (NGV) Pin bore diameter (piston) 0.8660827 - 0.8662402 in Pin diameter 0.8661811 - 0.8662598 in Piston pin length 2.425236 - 2.442126 in Pin-to-piston clearance 0.0001771654 in interference to 0.0015mm Pin-to-rod clearance 0.0003S43307 - -0.0009055118 in 9:1 ENGINES (GASOLINE) Pin bore diameter (piston) 0.8663976 - 0.8665748 in Pin diameter 0.8659449 - 0.8660236 in Piston pin-length 2.435827 - 2.445669 in Pin-to-piston clearance 0.0003740157 - 0.0006299213 in Pin-to-rod clearance 0.006299213 - 0.001496063 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2322 Piston Pin: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications 10:1 ENGINES (NGV) Piston ring-to-groove clearance, top 0.001181102 - 0.002755906 in Piston ring-to-groove clearance, intermediate 0.0007874016 - 0.002362205 in Piston ring-to-groove clearance, oil control 0.001181102 - 0.002755906 in Piston ring gap, top 0.005905512 - 0.01181102 in Piston ring gap, intermediate 0.005905512 - 0.01181102 in Piston ring gap, oil control 0.005905512 - 0.01181102 in 9:1 ENGINES (GASOLINE) Piston ring-to-groove clearance, top 0.0007874016 - 0.002362205 in Piston ring-to-groove clearance, intermediate 0.0007874016 - 0.002362205 in Piston ring-to-groove clearance, oil control 0.001181102 - 0.002755906 in Piston ring gap, top 0.005905512 - 0.01181102 in Piston ring gap, intermediate 0.005905512 - 0.01181102 in Piston ring gap, oil control 0.005905512 - 0.01181102 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2326 Piston Ring: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2334 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2335 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2339 Rocker Arm Assembly: Service and Repair Special Tools 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. 4. Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2340 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover Bolts Refer to Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH Valve Cover: Service and Repair LH Removal 1. Raise and support the vehicle. 2. Disconnect the Power Steering Pressure (PSP) switch electrical connector and the oil pressure sensor electrical connector. 3. Lower the vehicle. 4. Disconnect the cylinder head temperature sensor jumper wire connector. 5. Remove the bolt and the two studs and position the bracket out of the way. 6. Disconnect the Camshaft Position (CMP) sensor electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2346 7. Disconnect the generator electrical connector. 8. Disconnect the fuel charging wiring electrical connectors from the coils and the fuel injectors. 9. Disconnect the: - Idle Air Control (IAC) valve electrical connector. - Throttle Position (TP) sensor electrical connector. 10. Disconnect the: - 42-pin connector. - 16-pin connector. - transmission electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2347 11. Remove the six bolts and five studs and remove the valve cover. Installation 1. To install, reverse the removal procedure. - Apply sealant in the locations shown; use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2348 Valve Cover: Service and Repair RH Removal 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Disconnect the A/C compressor electrical connector. 4. Lower the vehicle. 5. Disconnect the A/C cycling switch connector. 6. Disconnect the fuel lines. 7. Disconnect the ignition coils electrical connectors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2349 8. Disconnect the fuel injector electrical connectors. 9. Remove the Positive Crankcase Ventilation (PCV) tube and position out of the way. 10. Disconnect the electrical connector. 11. Remove the Evaporative Emission (EVAP) canister purge valve. 12. Reposition the hold-down clamp and remove the hose from the bypass tube. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2350 13. 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. 14. Remove the studs, the bolts and the valve cover. Installation 1. To install, reverse the removal procedure. - Apply sealant in the locations shown; use Silicone Gasket and Sealant F7AZ-l955lEA or equivalent meeting Ford specification WSE-M4G323-A4. 2. Tighten in the sequence shown. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve guide inside diameter 0.277322 - 0.2761803 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve seat width-intake 0.08267692 - 0.07480292 in Valve seat width-exhaust 0.0267692 - 0.07480292 in Valve seat angle 45.00 deg Valve seat runout (TIR) 0.00984249 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve spring compression pressure-intake 633.3 - 701.3 N at 28.02 mm Valve spring compression pressure-exhaust 633.3 - 701.3 N at 28.02 mm Valve spring free length-intake 1.976372 in Valve spring free length-exhaust 1.976372 in Valve spring installed pressure-intake 272.1 - 306.1 N at 40.0 mm Valve spring installed pressure-exhaust 272.1 -306.1 N at 40.0 mm Valve spring installed pressure service limit-intake 274.6 N at 40.01 mm Valve spring installed pressure service limit-exhaust 274.6 N at 40.01 mm Valve spring out-of-square limit-intake 2.5 deg Valve spring out-of-square limit-exhaust 2.5 deg Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2360 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. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2361 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve stem guide clearance-intake 0.002716527 - 0.000787399 in Valve stem guide clearance-exhaust 0.003740146 - 0.001811024 in Valve head diameter-intake 1.751969 in Valve head diameter-exhaust 1.338583 in Valve face runout limit 0.001968498 in Valve face angle 45.5 deg Valve stem diameter-intake 0.2753929 - 0.2746055 in Valve stem diameter-exhaust 0.2744086 - 0.2735819 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2365 Valve: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt 6 Ribs Gasoline and natural gas 6K Poly V BeltTension is within specification if the tensioner is within the indicator markings Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2370 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by running the engine. 2. Inspect the drive belt for chunking, fraying and wear. 3. Cheek the drive belt for correct routing. The accessory drive: has a single serpentine drive belt. - has an automatic drive belt tensioner. - does not require adjustment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2373 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2374 Drive Belt: Component Tests and General Diagnostics Belt Tension Note: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Belt Tensioner Check the automatic drive belt tensioner: 1. With the engine off, check for correct drive belt routing. Correct as necessary. 2. Rotate the drive belt tensioner and check for a binding or seized condition. Install new components as necessary. Drive Belt Cracking/Chunking/Wear V-Ribbed Serpentine Drive Belt with Cracks Across Ribs. V-Ribbed With Chunks of Rib Missing Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2375 Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of the drive belt. With the engine running, check drive belt tucking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. - Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the drive belt tracking. - Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an incorrectly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: If the A/C discharge pressure goes above specifications: the A/C system is overcharged. - the A/C condenser core airflow is blocked. - If the A/C OFF equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. - If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water. A new drive belt does not have to be installed if no apparent damage has occurred. - The drive belt tensioner arm should rotate freely without binding. - If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, install a new drive belt. - If the drive belt tensioner is worn or damaged. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2376 Drive Belt: Service and Repair Removal and Installation 1. Rotate the tensioner clockwise and remove the drive belt. 2. To install, reverse the removal procedure. Refer to Component Locations for drive belt routing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 bolt and the belt tensioner. Installation 1. Install the belt tensioner. Tighten the bolt in two stages: - Stage 1: Tighten to 10 Nm (89 inch lbs.). - Stage 2: Tighten an additional 90 degrees. 2. Install the drive belt. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine Mounts - Unsatisfactory for Severe Conditions 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2384 Engine Mount: Specifications Motor mount to cross members bolts 39 - 53 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Engine Mount: Service and Repair Engine Mount 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount > Page 2387 1. Follow the removal procedure in reverse order. 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount > Page 2388 Engine Mount: Service and Repair Powertrain/Drivetrain Mount Neutralizing 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. Move the vehicle in forward and reverse (2-4 ft). CAUTION: Do not twist or strain the powertrain/drivetrain mounts. 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Idler pulley bolt 18 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2392 Idler Pulley: Service and Repair Removal and Installation 1. Remove the drive belt. 2. Remove the bolt and the belt idler pulley. 3. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure @ 200 Degrees F 40 - 70 psi Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 level indicator tube bolt 71 - 106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2400 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 seal. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil pan drain plug 98 - 143 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2408 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2409 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2410 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2413 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................... SAE 5W-20 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolts Refer to Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2417 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 pin-type retainer from the oil filter adapter. Remove the oil filter adapter. Remove the bolts. - Remove the oil filter adapter. Installation 1. Clean the sealing surfaces. 2. Install a new gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2418 3. Install the oil filter adapter and tighten the bolts in the sequence shown. 4. Install the oil pressure sensor. 1 Install the oil pressure sensor. 2 Connect the connector. 5. Install the oil bypass filter. 6. Lower the vehicle. 7. Fill the crankcase with clean Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 8. Connect the lower radiator hose. 9. Fill and bleed the cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts Refer to Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2422 Oil Pan: Service and Repair Oil Pan Special Tool(s) 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. Raise the vehicle. 10. Remove the RH engine mount bolt. 11. Remote the two LH engine mount bolts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2423 12. Remove the four nuts and support the exhaust. 13. Remove the bolt for the transmission line support bracket. 14. Loosen the nuts for the transmission mount. 15. Lower the vehicle. NOTE: The RH motor mount has a second bolt accessed from the top. 16. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2424 17. Using the special tool, raise the engine with a suitable floor crane. 18. Using the special tool, support the engine. 19. Raise the vehicle. 20. Remove the oil pan bolts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2425 21. Position the oil pan aside and remove the bolts from the oil pickup tube. 22. Remove the bolt from the oil pickup tube bracket. 23. Remove the O-ring and inspect. 24. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2426 3. Position the oil pickup tube and tighten the bolts. 4. Install and tighten the bolts. 5. Lower the vehicle. 6. 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2427 7. Remove the special tool. 8. Lower the engine 9. Remove the special tool. 10. Raise the vehicle. 11. Tighten the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2428 12. Install and tighten the bolt. 13. Reposition the exhaust and tighten the nuts. 14. Install and tighten the bolts. 15. Install and tighten the bolt. 16. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2429 17. Tighten the bolt. 18. Install the blower motor speed control. 19. Install the generator. 20. Install the EGR tube. 21. Connect the fuel lines. 22. Install the air cleaner outlet tube. 23. Install the wiper arm and pivot shaft assembly. 24. Install the drive belt. 25. Install the fan motor and shroud assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2436 Oil Pressure Warning Lamp/Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil pump screen cover and tube-to-oil pump screen cover and tube spacer bolt 18 ft.lb Oil pump screen cover and tube bolts 89 in.lb Oil pump screen cover and tube spacer 18 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 @ 200 Degrees F 40 - 70 psi Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2452 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 VIN W (2000)) 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 2453 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 VIN W (2000)) 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 2454 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 VIN W (2000)) 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 2455 ^ 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 VIN W (2000)) 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 2456 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 VIN W (2000)) 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 2457 ^ 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 VIN W (2000)) 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 VIN W (2000)) 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 2462 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2463 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 VIN W (2000)) 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 2464 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 VIN W (2000)) 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 2465 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 VIN W (2000)) 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 2466 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2467 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2473 If seepage is found, order one of the following Service Kits to repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2474 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2480 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 VIN W (2000)) 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 2481 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 VIN W (2000)) 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 2482 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 VIN W (2000)) 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 2483 ^ 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 VIN W (2000)) 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 2484 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 VIN W (2000)) 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 2485 ^ 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 VIN W (2000)) 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 VIN W (2000)) 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 2490 If seepage is found, order one of the following Service Kits to repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2491 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2496 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2497 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 VIN W (2000)) 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 2498 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 VIN W (2000)) 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 2499 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 VIN W (2000)) 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 2500 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2501 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2507 If seepage is found, order one of the following Service Kits to repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2508 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2514 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 VIN W (2000)) 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 2515 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 VIN W (2000)) 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 2516 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 VIN W (2000)) 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 2517 ^ 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 VIN W (2000)) 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 2518 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 VIN W (2000)) 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 2519 ^ 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 VIN W (2000)) 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 VIN W (2000)) 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 2524 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2525 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 VIN W (2000)) 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 2526 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 VIN W (2000)) 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 2527 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 VIN W (2000)) 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 2528 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2529 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2530 Intake Manifold: Specifications Intake Manifold Bolts 15-22 ft.lb Throttle Body Bolts 71-106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2531 Intake Manifold: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Drain the engine cooling system. 3. Remove the air cleaner outlet tube. 4. Disconnect the fuel line. 5. Remove the wiper arm and pivot shaft. 6. Remove the drive belt. 7. Raise the vehicle on a hoist. 8. Disconnect the electrical connector at the Crankshaft Position (CKP) sensor. - Disconnect the pin-type retainer from the A/C compressor bracket. 9. Disconnect the electrical connector from the A/C compressor. 10. Remove the oil bypass filter. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2532 11. Disconnect the oil pressure sensor electrical connector and the Power Steering Pressure (PSP) switch electrical connector. 12. Disconnect the Exhaust Gas Recirculation (EGR) tube from the exhaust manifold. 13. Lower the vehicle. 14. Disconnect the two differential pressure feedback EGR hoses. 15. Disconnect the RH heated oxygen sensor electrical connector. 16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2533 17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors. 18. Disconnect the accelerator cable and the speed control actuator cable. 19. Remove the cables from the EGR tube heat shield and position out of the way. 20. Remove the bolts and the EGR tube heat shield. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2534 21. Disconnect the Evaporative Emissions (EVAP) return tube, the main chassis vacuum supply line, and the EGR valve vacuum supply. 22. Disconnect the Positive Crankcase Ventilation (PCV) tube assembly at two locations and remove. 23. Disconnect the electrical connector from the EGR vacuum regulator solenoid. 24. Disconnect the vacuum line from the EVAP canister purge valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2535 25. Disconnect the generator cable and electrical connector. 26. Remove the bolts and the generator mounting bracket. 27. Remove the upper radiator hose. 28. Disconnect the electrical connector from the Idle Air Control (IAC) valve and the Throttle Position (TP) sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2536 29. Disconnect the heater water hose. 30. Disconnect the EGR tube from the EGR valve. 31. Note: The LH heated oxygen sensor and the transmission electrical connectors are attached to the wiring bracket and must be separated from the bracket. Remove the wiring bracket. Disconnect the wiring connectors. - Separate the transmission harness from the stud. - Remove the nut and the bolt and remove the bracket. 32. Remove the bolts and the throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2537 33. Separate the fuel charging wiring pin-type retainer from the crash bracket. 34. Remove the bolt and the stud and remove the crash bracket. 35. Disconnect the vacuum lines and remove the vacuum harness. 36. Remove the studs and the fuel injection supply manifold and fuel injectors as an assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2538 37. Remove the bolts and the ignition coils. 38. Remove the bolts and the water outlet adapter. 39. Remove the water thermostat. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2539 40. Remove the bolts and the intake manifold. 41. Remove the intake manifold gaskets. 42. Clean the sealing surfaces. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2540 1. Install the new intake manifold gaskets. 2. Install the intake manifold and hand-tighten the bolts at the locations shown. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2541 3. Install the ignition coils and tighten the bolts. 4. Install the fuel injection supply manifold and tighten the studs. 5. Install the crash bracket and loosely install the bolt and the stud. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2542 6. Install the water thermostat. 7. Install the water outlet adapter and loosely install the bolts. 8. Tighten the bolts in sequence. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2543 9. Tighten the stud. 10. Tighten the bolts. 11. Install the throttle body and tighten the bolts. 12. Install the wiring bracket. - Position the bracket. - Install the nut and the bolt - Attach the wiring connectors to the wiring bracket. - Connect the LH heated oxygen sensor electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2544 13. Connect the EGR tube to the EGR valve. 14. Position the EGR tube heat shield and install the bolts. 15. Connect the heater water hose and position the clamp. 16. Connect the electrical connector to the: - IAC control valve. - TP sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2545 17. Install the upper radiator hose: - Install the upper radiator hose. Position the clamps. 18. Connect the generator electrical connector and the battery lead. 19. Install the generator mounting bracket: - Position the generator mounting bracket. - Install the bolts. 20. Position the vacuum harness and connect the vacuum line to the EVAP canister purge valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2546 21. Connect the electrical connector and the vacuum lines to the EGR vacuum regulator solenoid. 22. Install and connect the PCV tube. 23. Connect the vacuum lines for the EVAP canister purge valve, the main chassis vacuum supply line and the EGR valve. 24. Reposition and attach the cables to the EGR tube heat shield. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2547 25. Connect the accelerator cable and the speed control actuator cable. 26. Connect the fuel charging wiring electrical connectors to the eight fuel injectors. 27. Connect the fuel charging wiring electrical connectors to the eight ignition coils. 28. Connect the RH heated oxygen sensor electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2548 29. Connect the two differential pressure feedback EGR hoses. 30. Raise the vehicle. 31. Connect the EGR tube to the exhaust manifold connector. 32. Connect the electrical connector to the oil pressure sensor and the PSP switch. 33. Install the oil bypass filter. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2549 34. Connect the electrical connector to the A/C compressor. 35. Connect the electrical connector to the CKP sensor. - Connect the pin-type retainer to the A Compressor bracket. 36. Lower the vehicle. 37. Install the drive belt. 38. Install the wiper arm and pivot shaft. 39. Connect the fuel line. 40. Install the air cleaner outlet tube. 41. Connect the battery ground cable. 42. Check the engine oil. 43. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2554 Oil Pressure Warning Lamp/Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2559 3. Use the (A) Rear Crank Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 4. Use the (A) Rear Crank 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-MSB392-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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2560 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-MSB392-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 WSE-M4G323-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 Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crank Seal Replacer and the Rear Crankshaft Adapter to install the rear main seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2561 6. With the Rear Crankshaft Adapter still installed, use the Rear Crank Slinger Replacer and the Rear Crank Seal Replacer to install the rear main seal slinger. 7. Install the flywheel. 8. Install the transmission. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2570 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2571 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 VIN W (2000)) 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 2572 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2578 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2579 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2580 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2585 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2586 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 VIN W (2000)) 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: > 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 VIN W (2000)) 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: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2592 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 VIN W (2000)) 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: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2593 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 VIN W (2000)) 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 Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2597 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt 81 - 95 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 2610 Camshaft Gear/Sprocket: Specifications Crankshaft Sprocket Bolt 81-95 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Customer Interest for Timing Chain: > 03-15-7 > Aug > 03 > Engine - Timing Chain Grinding Noise Timing Chain: Customer Interest Engine - Timing Chain Grinding Noise Article No. 03-15-7 08/04/03 ^ ENGINE - 4.6L - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA ^ NOISE - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA FORD: 2000-2003 CROWN VICTORIA MERCURY: 2000-2003 GRAND MARQUIS ISSUE Some 4.6L 2V engines may exhibit a grinding type noise from the timing chain area. This may be caused by excessive wear of the timing chain tensioner arms. The tensioner arm has an aluminum base with a nylon surface. Another indication of this condition may be fine nylon and/or aluminum particles present in the engine oil. ACTION Inspect the timing chain and arms to determine if excessive wear exists. If this condition is present, replace the timing chains, tensioners and the tensioner arms. Refer to the following Service Information for details. SERVICE INFORMATION Refer to Workshop Manual Section 303-01A for correct replacement service procedures. ^ Fine finish timing chains - part F5LY-6268-A ^ Tensioner - 2000 RH part F6AZ-6L266-DA, LH part F6AZ-6L266-CA ^ Tensioner - 2001-2003 RH part 1L3Z-6L266-AA, LH part XL1Z-6L266-AA ^ Tensioner arms - LH part 1L2Z-6L253-AA, RH part 1L2Z-6L253-BA Remove residual nylon/aluminum particles by performing an engine oil change and replacing the oil filter. If wear has progressed through tensioner arm into tensioner piston, remove oil pan from engine and clean debris from oil pick up tube. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 03-15-7 > Aug > 03 > Engine - Timing Chain Grinding Noise Timing Chain: All Technical Service Bulletins Engine - Timing Chain Grinding Noise Article No. 03-15-7 08/04/03 ^ ENGINE - 4.6L - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA ^ NOISE - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA FORD: 2000-2003 CROWN VICTORIA MERCURY: 2000-2003 GRAND MARQUIS ISSUE Some 4.6L 2V engines may exhibit a grinding type noise from the timing chain area. This may be caused by excessive wear of the timing chain tensioner arms. The tensioner arm has an aluminum base with a nylon surface. Another indication of this condition may be fine nylon and/or aluminum particles present in the engine oil. ACTION Inspect the timing chain and arms to determine if excessive wear exists. If this condition is present, replace the timing chains, tensioners and the tensioner arms. Refer to the following Service Information for details. SERVICE INFORMATION Refer to Workshop Manual Section 303-01A for correct replacement service procedures. ^ Fine finish timing chains - part F5LY-6268-A ^ Tensioner - 2000 RH part F6AZ-6L266-DA, LH part F6AZ-6L266-CA ^ Tensioner - 2001-2003 RH part 1L3Z-6L266-AA, LH part XL1Z-6L266-AA ^ Tensioner arms - LH part 1L2Z-6L253-AA, RH part 1L2Z-6L253-BA Remove residual nylon/aluminum particles by performing an engine oil change and replacing the oil filter. If wear has progressed through tensioner arm into tensioner piston, remove oil pan from engine and clean debris from oil pick up tube. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2624 Timing Chain: Diagrams 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 Make sure that the copper marks on the timing chain are lined up with the corresponding dots on the crankshaft sprockets and the camshaft sprockets. Make sure that the (A) camshaft sprocket keyway is 90 degrees from the (B) valve cover mounting surface. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2625 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2626 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2627 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2628 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2629 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2630 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2631 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Page 2632 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Technical Service Bulletins > Customer Interest for Timing Chain Guide: > 03-15-7 > Aug > 03 > Engine - Timing Chain Grinding Noise Timing Chain Guide: Customer Interest Engine - Timing Chain Grinding Noise Article No. 03-15-7 08/04/03 ^ ENGINE - 4.6L - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA ^ NOISE - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA FORD: 2000-2003 CROWN VICTORIA MERCURY: 2000-2003 GRAND MARQUIS ISSUE Some 4.6L 2V engines may exhibit a grinding type noise from the timing chain area. This may be caused by excessive wear of the timing chain tensioner arms. The tensioner arm has an aluminum base with a nylon surface. Another indication of this condition may be fine nylon and/or aluminum particles present in the engine oil. ACTION Inspect the timing chain and arms to determine if excessive wear exists. If this condition is present, replace the timing chains, tensioners and the tensioner arms. Refer to the following Service Information for details. SERVICE INFORMATION Refer to Workshop Manual Section 303-01A for correct replacement service procedures. ^ Fine finish timing chains - part F5LY-6268-A ^ Tensioner - 2000 RH part F6AZ-6L266-DA, LH part F6AZ-6L266-CA ^ Tensioner - 2001-2003 RH part 1L3Z-6L266-AA, LH part XL1Z-6L266-AA ^ Tensioner arms - LH part 1L2Z-6L253-AA, RH part 1L2Z-6L253-BA Remove residual nylon/aluminum particles by performing an engine oil change and replacing the oil filter. If wear has progressed through tensioner arm into tensioner piston, remove oil pan from engine and clean debris from oil pick up tube. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Guide: > 03-15-7 > Aug > 03 > Engine - Timing Chain Grinding Noise Timing Chain Guide: All Technical Service Bulletins Engine - Timing Chain Grinding Noise Article No. 03-15-7 08/04/03 ^ ENGINE - 4.6L - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA ^ NOISE - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA FORD: 2000-2003 CROWN VICTORIA MERCURY: 2000-2003 GRAND MARQUIS ISSUE Some 4.6L 2V engines may exhibit a grinding type noise from the timing chain area. This may be caused by excessive wear of the timing chain tensioner arms. The tensioner arm has an aluminum base with a nylon surface. Another indication of this condition may be fine nylon and/or aluminum particles present in the engine oil. ACTION Inspect the timing chain and arms to determine if excessive wear exists. If this condition is present, replace the timing chains, tensioners and the tensioner arms. Refer to the following Service Information for details. SERVICE INFORMATION Refer to Workshop Manual Section 303-01A for correct replacement service procedures. ^ Fine finish timing chains - part F5LY-6268-A ^ Tensioner - 2000 RH part F6AZ-6L266-DA, LH part F6AZ-6L266-CA ^ Tensioner - 2001-2003 RH part 1L3Z-6L266-AA, LH part XL1Z-6L266-AA ^ Tensioner arms - LH part 1L2Z-6L253-AA, RH part 1L2Z-6L253-BA Remove residual nylon/aluminum particles by performing an engine oil change and replacing the oil filter. If wear has progressed through tensioner arm into tensioner piston, remove oil pan from engine and clean debris from oil pick up tube. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Technical Service Bulletins > Page 2646 Timing Chain Guide: Specifications Timing chain guide bolts 71 - 106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 03-15-7 > Aug > 03 > Engine - Timing Chain Grinding Noise Timing Chain Tensioner: Customer Interest Engine - Timing Chain Grinding Noise Article No. 03-15-7 08/04/03 ^ ENGINE - 4.6L - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA ^ NOISE - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA FORD: 2000-2003 CROWN VICTORIA MERCURY: 2000-2003 GRAND MARQUIS ISSUE Some 4.6L 2V engines may exhibit a grinding type noise from the timing chain area. This may be caused by excessive wear of the timing chain tensioner arms. The tensioner arm has an aluminum base with a nylon surface. Another indication of this condition may be fine nylon and/or aluminum particles present in the engine oil. ACTION Inspect the timing chain and arms to determine if excessive wear exists. If this condition is present, replace the timing chains, tensioners and the tensioner arms. Refer to the following Service Information for details. SERVICE INFORMATION Refer to Workshop Manual Section 303-01A for correct replacement service procedures. ^ Fine finish timing chains - part F5LY-6268-A ^ Tensioner - 2000 RH part F6AZ-6L266-DA, LH part F6AZ-6L266-CA ^ Tensioner - 2001-2003 RH part 1L3Z-6L266-AA, LH part XL1Z-6L266-AA ^ Tensioner arms - LH part 1L2Z-6L253-AA, RH part 1L2Z-6L253-BA Remove residual nylon/aluminum particles by performing an engine oil change and replacing the oil filter. If wear has progressed through tensioner arm into tensioner piston, remove oil pan from engine and clean debris from oil pick up tube. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-15-7 > Aug > 03 > Engine Timing Chain Grinding Noise Timing Chain Tensioner: All Technical Service Bulletins Engine - Timing Chain Grinding Noise Article No. 03-15-7 08/04/03 ^ ENGINE - 4.6L - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA ^ NOISE - GRINDING TYPE NOISE FROM ENGINE TIMING CHAIN AREA FORD: 2000-2003 CROWN VICTORIA MERCURY: 2000-2003 GRAND MARQUIS ISSUE Some 4.6L 2V engines may exhibit a grinding type noise from the timing chain area. This may be caused by excessive wear of the timing chain tensioner arms. The tensioner arm has an aluminum base with a nylon surface. Another indication of this condition may be fine nylon and/or aluminum particles present in the engine oil. ACTION Inspect the timing chain and arms to determine if excessive wear exists. If this condition is present, replace the timing chains, tensioners and the tensioner arms. Refer to the following Service Information for details. SERVICE INFORMATION Refer to Workshop Manual Section 303-01A for correct replacement service procedures. ^ Fine finish timing chains - part F5LY-6268-A ^ Tensioner - 2000 RH part F6AZ-6L266-DA, LH part F6AZ-6L266-CA ^ Tensioner - 2001-2003 RH part 1L3Z-6L266-AA, LH part XL1Z-6L266-AA ^ Tensioner arms - LH part 1L2Z-6L253-AA, RH part 1L2Z-6L253-BA Remove residual nylon/aluminum particles by performing an engine oil change and replacing the oil filter. If wear has progressed through tensioner arm into tensioner piston, remove oil pan from engine and clean debris from oil pick up tube. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2665 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2666 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2672 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Timing Chain Tensioner: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2673 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Page 2674 Timing Chain Tensioner: Specifications Timing chain tensioner bolts 18 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Refer to Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2678 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 four bolts. 8. Lower the vehicle. 9. Remove the crankshaft front seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2679 10. Remove the bolt and the belt idler pulley. 11. Remove the bolts and the 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2680 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-MSB392-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 WSE-M4G323-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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2681 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2682 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.). 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2683 7. Loosely install the front oil pan bolts. 8. Note: Make sure to tighten the bolts in two stages. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten to 20 Nm (15 ft. lbs.) - Stage 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2684 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 Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 2693 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 790 - 815 RPM Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 element. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2705 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2706 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2710 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2719 Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2720 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2721 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2722 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2723 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2724 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2725 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2729 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 15 - 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump > Page 2737 Water Pump: Specifications Water pump pulley bolts 15 - 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2738 Water Pump: Service and Repair Removal and Installation 1. Drain the coolant. 2. Loosen the bolts. 3. Remove the belt. 4. Remove the bolts and the water pump pulley. 5. Remove the water pump. 6. Clean the water pump mounting surface. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2739 7. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the O-ring seal can occur, causing the water pump to leak. Note: Install a new O-ring seal and lubricate with 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2745 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Fluid Capacity 15 L Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2748 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water bypass tube stud 15 - 22 ft.lb Water outlet adapter 18 ft.lb Water outlet connection bolts 18 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Torque Specifications Degas bottle bolts ................................................................................................................................ ........................................... 8-12 Nm (45-61 lb.in) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2758 Coolant Reservoir: Service and Repair Removal and Installation 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. 4. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Motor Service Procedure > Page 2764 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Motor Service Procedure > Page 2765 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Motor Service Procedure > Page 2766 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Motor Service Procedure > Page 2767 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Motor Service Procedure > Page 2768 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Page 2769 Radiator Cooling Fan Motor: Service and Repair Removal 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. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay > Page 2774 Radiator Cooling Fan Motor Relay: Locations Cooling Fan Low Relay Diagram 11-03 Cooling Fan Low Relay is direct wired to the battery junction box. Wire color code is RD, RD/OR, DB and YE/Bk. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay > Page 2775 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2776 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2777 Radiator Cooling Fan Motor Relay: Testing and Inspection COOLING FAN RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Removal 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. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2785 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2786 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2787 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2788 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 2792 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 2793 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 2794 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations > Page 2798 Temperature Sensor (Gauge): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations > Page 2799 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 2803 Fan Shroud: Service and Repair Removal 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. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 2812 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 VIN W (2000)) 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 2813 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 VIN W (2000)) 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 VIN W (2000)) 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 2819 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 VIN W (2000)) 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 2820 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2821 Heating And Ventilation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2822 Heater Core: Diagrams Vacuum Schematic - Manual A/C Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2823 Vacuum Schematic - Electronic Automatic Temperature Control Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2824 Heater Core: Service Precautions 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. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2825 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2826 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2827 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2828 Heater Core: Service and Repair 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. 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 VIN W (2000)) 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 VIN W (2000)) 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 2837 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 VIN W (2000)) 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 2838 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 VIN W (2000)) 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 VIN W (2000)) 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 2844 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 VIN W (2000)) 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 2845 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2846 Heating And Ventilation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2847 Heater Hose: Service and Repair REMOVAL 1. Drain the radiator. For additional information, refer to Cooling System. 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Conventional Temperature Gauge: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Conventional > Page 2853 Temperature Gauge: Description and Operation Electronic 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 200 ohms to 13,000 ohms. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2854 Temperature Gauge: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications Radiator: Specifications Radiator bracket bolts 6 - 7 ft.lb Radiator to transmission cooler to A/C condenser bolts 43 - 61 ft.lb Radiator support bracket bolts 18 - 26 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2858 Radiator: Service and Repair Removal and Installation 1. Raise and support the vehicle. 2. Drain the engine cooling system. 3. Remove the fan blade, fan motor and fan shroud assembly. 4. Release the hold-downs and remove the 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2859 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. 10. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay > Page 2865 Radiator Cooling Fan Motor Relay: Locations Cooling Fan Low Relay Diagram 11-03 Cooling Fan Low Relay is direct wired to the battery junction box. Wire color code is RD, RD/OR, DB and YE/Bk. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Cooling Fan High Relay > Page 2866 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2867 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2868 Radiator Cooling Fan Motor Relay: Testing and Inspection COOLING FAN RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 > Page 2874 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2875 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2876 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 2877 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2881 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2882 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2883 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations > Page 2887 Temperature Sensor (Gauge): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations > Page 2888 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Conventional Temperature Gauge: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Conventional > Page 2893 Temperature Gauge: Description and Operation Electronic 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 200 ohms to 13,000 ohms. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2894 Temperature Gauge: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 F Water thermostat full open temperature 219 F Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2898 Thermostat: Service and Repair Removal and Installation 1. Drain the coolant below the water thermostat. 2. Remove the engine appearance cover. 3. Remove the bolts, the water outlet adapter and hose and position out of the way. 4. Remove the water thermostat and the O-ring seal from the intake manifold. - Inspect the O-ring seal, install a new seal if necessary. 5. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 15 - 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump > Page 2903 Water Pump: Specifications Water pump pulley bolts 15 - 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2904 Water Pump: Service and Repair Removal and Installation 1. Drain the coolant. 2. Loosen the bolts. 3. Remove the belt. 4. Remove the bolts and the water pump pulley. 5. Remove the water pump. 6. Clean the water pump mounting surface. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2905 7. CAUTION: Do not rotate the water pump housing once installed in the engine. Damage to the O-ring seal can occur, causing the water pump to leak. Note: Install a new O-ring seal and lubricate with 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2911 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2912 ^ 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2913 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2914 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2915 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2916 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2917 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2918 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2919 ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2920 ^ 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) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2921 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2922 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2923 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2924 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2925 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2926 Catalytic Converter: Specifications Three Way Catalytic Converter to Exhaust Manifold Nuts 25 - 33 ft.lb Three Way Catalytic Converter to Inlet Pipe Flange Nuts 25 - 33 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2927 Catalytic Converter: Description and Operation Overview Generic Catalyst and Exhaust System The Catalytic Converter and Exhaust Systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides Of Nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either Platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can br brst accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2928 the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the H02S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the H02S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2929 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 TWC. - Remove the nuts, bolts, damper and gasket. - Remove the TWC. Installation 1. Position the Three Way Catalytic Converters (TWC) and install the two nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2930 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold to converter nuts 20 - 30 ft.lb Exhaust Manifold 17 - 20 ft.lb LH Sequence --RH Sequence --- Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH Exhaust Manifold: Service and Repair LH 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 2936 Exhaust Manifold: Service and Repair RH 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 VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: 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. 4. Remove the tailpipe assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2940 - 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. 3. Install the exhaust hanger insulators. Install the tailpipe into the exhaust hanger insulator. 4. Install the muffler to the inlet pipe. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2941 - Position the clamp. - Install the nuts. 5. Install the muffler-to-tailpipe gasket, nuts, and bolts. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair Heat Shield: Service and Repair 1. Disconnect the battery cable. 2. Raise the vehicle. 3. Inspect the catalytic converter and muffler for loose or missing heat shields. 4. Install worm clamps for heat shields that are loose. - Use one of the following clamps: FOTZ-5A231-A or W705949-S300. - Trim off the excess ear of the worm clamp. 5. If the heat shields are missing, install new heat shields. If new heat shields are not available, install a new catalytic converter. 6. Lower the vehicle. 7. Reconnect the battery cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler-to-Tailpipe Flange Nuts 25 - 33 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2948 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. 4. Remove the tailpipe assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2949 - 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. 3. Install the exhaust hanger insulators. Install the tailpipe into the exhaust hanger insulator. 4. Install the muffler to the inlet pipe. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2950 - Position the clamp. - Install the nuts. 5. Install the muffler-to-tailpipe gasket, nuts, and bolts. 6. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2958 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 VIN W (2000)) 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 2959 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 VIN W (2000)) 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 2960 Powertrain Control Module: Specifications Powertrain control module electrical connector bolt 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2961 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2962 Powertrain Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2963 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2964 Powertrain Control Module: Description and Operation The PCM carries out the following functions: ^ accepts input from various engine sensors to complete the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 2965 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and remove the Powertrain Control Module (PCM) electrical connector. 3. Remove the PCM cover nuts. 4. Remove the PCM cover. 5. Remove the under dash sight cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Service and Repair > Procedures > Page 2968 6. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Service and Repair > Procedures > Page 2969 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2973 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2974 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2984 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2986 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2987 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2988 Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2992 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2993 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2996 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2997 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3001 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3002 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3008 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3009 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3010 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3011 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3015 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3016 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3017 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 > Page 3024 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3025 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3026 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3027 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3031 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3032 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3035 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3036 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3040 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3041 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3042 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications Fuel Level Sensor: Specifications Fuel Level Sensor 4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications > Page 3046 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information Fuel Tank Pressure Sensor: Technician Safety Information WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information > Page 3055 Fuel Tank Pressure Sensor: Vehicle Damage Warnings CAUTION: ^ The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3056 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. The fuel tank pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. ^ is located in the fuel tank and is serviced as a separate item. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3057 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Partially drain and lower the fuel tank. For additional information, refer to Fuel Tank/Service and Repair. See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair CAUTION: The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. 3. Push down and rotate the fuel tank pressure sensor counterclockwise to remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor Intake Air Temperature Sensor: Locations Ambient Air Temperature Sensor Center front of vehicle, on front of upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor > Page 3062 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3063 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3064 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3078 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3079 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3080 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3081 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3082 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3083 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3084 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3085 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3086 ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3087 ^ 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) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3088 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3089 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3090 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3091 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3092 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3093 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) - Front 41 Nm Heated Oxygen Sensor (HO2S) - Rear 41 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3094 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3097 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3098 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3099 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3112 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3113 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the powertrain control module used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the powertrain control module used to calculate catalytic converter integrity. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front Heated Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Service Tool(s) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the right side Heated Oxygen Sensor (HO2S) electrical connector. 3. Disconnect the left side HO2S electrical connector. 4. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 5. Using the special tool, remove the HO2S. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 3116 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 3117 Heated Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Service Tool(S) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 4. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9LA94-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Page 3118 Heated Oxygen Sensor: Tools and Equipment EGO Sensor Wrench EGO Sensor Wrench Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3125 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3129 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3130 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3134 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3135 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3136 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3137 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3138 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 3144 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 VIN W (2000)) 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 3145 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 VIN W (2000)) 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 3146 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 VIN W (2000)) 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 3147 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3148 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3149 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 VIN W (2000)) 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 3150 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 VIN W (2000)) 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 3151 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 VIN W (2000)) 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 3152 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 VIN W (2000)) 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 3153 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 VIN W (2000)) 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 3154 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 VIN W (2000)) 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 3155 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3156 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3157 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3158 Vehicle Speed Sensor: Electrical Diagrams Diagram 64-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3159 Diagram 64-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3160 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 3165 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3170 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3171 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3172 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3173 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws 1.0 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3180 Inertia Fuel Shutoff Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3181 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3182 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 3183 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Open the luggage compartment door. 2. Disconnect the connector from the Inertia Fuel Shutoff (IFS) switch. 3. Remove the retaining screws from the IFS switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3187 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3188 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3193 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3194 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3195 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3199 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3200 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3203 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3204 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 3210 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3211 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 VIN W (2000)) 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 3212 ^ 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 VIN W (2000)) 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 3213 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 VIN W (2000)) 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 3214 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 VIN W (2000)) 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 > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Installation Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 3217 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Installation 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. 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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 VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 3218 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. Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 3219 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. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Ignition Lock Cylinder - Functional > Page 3220 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 3232 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 790 - 815 RPM Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 element. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3244 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3245 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3249 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3258 Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3259 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3260 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3261 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3262 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3263 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3264 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3268 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine - the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, 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. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3276 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3277 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3278 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3279 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor Intake Air Temperature Sensor: Locations Ambient Air Temperature Sensor Center front of vehicle, on front of upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor > Page 3284 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3285 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3286 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3290 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3291 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3292 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3299 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3300 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3301 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3302 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3306 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3307 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3310 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3311 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations Component Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 3335 EGR Backpressure Transducer: 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 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 VIN W (2000)) 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 VIN W (2000)) 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 3340 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 VIN W (2000)) 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 3341 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3342 Powertrain Control Module: Specifications Powertrain control module electrical connector bolt 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3343 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3344 Powertrain Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3345 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3346 Powertrain Control Module: Description and Operation The PCM carries out the following functions: ^ accepts input from various engine sensors to complete the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3347 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and remove the Powertrain Control Module (PCM) electrical connector. 3. Remove the PCM cover nuts. 4. Remove the PCM cover. 5. Remove the under dash sight cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3350 6. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3351 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3355 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3356 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3357 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications Fuel Level Sensor: Specifications Fuel Level Sensor 4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications > Page 3361 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information Fuel Tank Pressure Sensor: Technician Safety Information WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information > Page 3370 Fuel Tank Pressure Sensor: Vehicle Damage Warnings CAUTION: ^ The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3371 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. The fuel tank pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. ^ is located in the fuel tank and is serviced as a separate item. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3372 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Partially drain and lower the fuel tank. For additional information, refer to Fuel Tank/Service and Repair. See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair CAUTION: The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. 3. Push down and rotate the fuel tank pressure sensor counterclockwise to remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3376 Idle Air Control Valve: Description and Operation Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly with Vent/Filter Hitachi Idle Air Control (IAC) Valve Assembly with Air-Assist Injectors The Idle Air Control (IAC) valve assembly controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the AC duty cycle in order to achieve the desired rpm. On applications with air-assisted injectors, the IAC valve also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3377 NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3378 Idle Air Control Valve: Testing and Inspection Idle Air Control Valve Noise Test 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an EngineEAR probe near the IAC valve 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 IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. For further information concerning the diagnosis of this component and that system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3379 Idle Air Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Disconnect the Idle Air Control (IAC) valve electrical connector. 4. Remove the IAC valve hose. 5. Remove the IAC valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications Multiplex Communication Network: Specifications Heat shrink tube overlap ...................................................................................................................... ..................................................... 12.7 mm (0.5 inch) Wire insulation removal length (twist side) .............................................................................................................................................. 37.2 mm (1.5 inch) Wire insulation removal length (receiving side) ..................................................................................................................................... 19.5 mm (0.75 inch) Raychem SCT(R) heat shrink tubing, Motorcraft part number WT-5627 .................................................................................................. ESB-M99D56-A2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications > Page 3383 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 Multiplex Communication Network: Electrical Diagrams Diagram 14-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 Diagram 14-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Page 3402 Multiplex Communication Network: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Multiplex Communication Network: Description and Operation Module Communications Network 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3405 communications network which is a single-wire network (Circuit 70 [LB/W]). Both networks can be connected to the scan tool 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 the scan tool communicates to modules on the ISO 9141 communication network, the scan tool 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 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. For additional information, refer to Air Bag Systems. 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. For additional information on interior lighting, refer to Lighting and Horns. For additional information on exterior lighting, refer to Lighting and Horns. For additional information on anti-theft, refer to Antitheft and Alarm Systems. For additional information on warning chimes, refer to Instrument Panel, Gauges and Warning Indicators. 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. For additional information, refer to Heating and Air Conditioning. 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. For additional information, refer to Symptom Charts in the Computers and Control Systems. 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). For additional information, refer to Pinpoint Tests in Computers and Control Systems. 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. For additional information, refer to Antilock Brake System. 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. For additional information on anti-theft, refer to Antitheft and Alarm Systems. Module Configuration Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3406 Some modules support the ability to change specified factory configuration settings and preset preference items. The process used to change the settings and customer preference items is module configuration. There are three different methods of module configuration. ^ Programmable Module Installation (PMI) ^ customer preference items ^ manufacturer options There are three storage locations for module configuration information. One primary storage location and two secondary (or backup) storage locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3407 ^ Primary location is the memory of the specific module. ^ First backup location is the VID block memory of the Powertrain Control Module (PCM). ^ Second backup is the As-Built Data Center. During PMI, the scan tool will attempt to extract the module configuration information from the module to be changed. If this is unsuccessful, the scan tool will use the first backup and attempt to extract the module configuration information from the VID block in the PCM. If this also fails, the scan tool will display instructions to contact the As-Built Data Center. This is the only time the As-Built Data Center should be contacted. Programmable Module Installation (PMI) NOTE: If the powertrain control module (PCM) needs to have a powertrain calibration flash programmed, refer to Computers and Control Systems. Make sure to use the flash cable when programming calibrations or running a PMI routine on the PCM. The PMI configuration method is used when a new programmable module is to be installed. During the PMI routine the scan tool attempts to gather two pieces of information: ^ Option content information from the old module. (module configuration and customer preference settings) ^ The Vehicle Identification Number (VIN) from the PCM. During PMI the scan tool first looks to the PCM for the VIN number of the vehicle. Once the VIN is retrieved the scan tool will carry out a self-test of the suspect module to determine if the module has been configured. ^ If DTC B2477 is present the module does not contain complete configuration information. The PMI routine will then halt and give instructions on how to proceed. ^ If DTC B2477 is not present the module will allow the scan tool to retrieve its option content information. The scan tool will then store the option content information and the VIN. The scan tool can store the combined option content information and VIN for only one module at a time. Once information is stored, the scan tool cannot be used to retrieve any other option content information without erasing the previous option content information. Make sure the new module is onhand for installation before retrieving option content information data from the old module. After the new module is installed, use the scan tool to restore the option content information into the new module. Vehicle Identification (VID) Block NOTE: ^ If the Powertrain Control Module (PCM) needs to have a powertrain calibration flash programmed, refer to Computers and Control Systems. Make sure to use the fash cable when programming calibrations or running a PMI routine on the PCM. ^ When carrying out a PMI routine on any non-PCM module, use the OBDII cable. ^ Flash programming powertrain calibrations onto the PCM is different than PMI. It has no effect on the backup data in the VID block memory area of the PCM. The PCM contains a memory area called a Vehicle Identification (VID) block. A portion of the VID block is used to store the backup data for each programmable module on the vehicle. The VID block is the first backup of information when using the PMI configuration method. If the scan tool cannot retrieve option content information from the suspect module, the scan tool will attempt to extract backup information from the VID block of the PCM. The VID block is not related to or effected by the powertrain calibration information stored in the PCM. If a new powertrain calibration has been flashed onto the PCM, the VID block will not be affected. If using the PMI routine to install a new PCM, the scan tool will reprogram only VID information. The engine calibration information may still need to be flashed. For more information, refer to Computers and Control Systems for flash programming information. As-Built Data Center The As-Built Data Center keeps a record of the vehicle configuration in a database retrievable using the VIN. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center will always reflect the original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the scan tool. Customer Preference Items This method is used to enable or disable module-controlled items or systems to suit the preference of the customer. Not all features controlled by the module are listed in this configuration method. Refer to the Module Configuration Index for a list of features per module. If an item is changed using the customer preference items configuration method, the changed information will not be stored in the PCM VID block. The VID block will retain the original settings as they were recorded when the vehicle left the factory. Manufacturer Options This method of configuration is used on modules that do not support PMI. This method is used to enable or disable module-configurable features to set module option content of the vehicle and the preference of the customer. Refer to the Module Configuration Index for a list of features per Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3408 module. If an item is changed using the manufacturer options configuration method, the changed information will not be stored in the PCM VID block. The VID block will retain the original settings as they were recorded when the vehicle left the factory. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3409 Multiplex Communication Network: Description and Operation Principles and 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 the scan tool by one connector called Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3410 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 the scan tool communicates to modules on the ISO 9141 communication network, the scan tool 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 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. For additional information, refer to Air Bag Systems. 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. For additional information on interior lighting, refer to Lighting and Horns. For additional information on exterior lighting, refer to Lighting and Horns. For additional information on anti-theft, refer to Antitheft and Alarm Systems. For additional information on warning chimes, refer to Instrument Panel, Gauges and Warning Indicators. 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. For additional information, refer to Heating and Air Conditioning. 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. For additional information, refer to Symptom Charts in the Computers and Control Systems. 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). For additional information, refer to Pinpoint Tests in Computers and Control Systems. 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. For additional information, refer to Antilock Brake System. 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. For additional information on anti-theft, refer to Antitheft and Alarm Systems. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3411 Multiplex Communication Network: Description and Operation Principles of Operation Some modules support the ability to change specified factory configuration settings and preset preference items. The process used to change the settings and customer preference items is module configuration. There are three different methods of module configuration. ^ Programmable Module Installation (PMI) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3412 ^ customer preference items ^ manufacturer options There are three storage locations for module configuration information. One primary storage location and two secondary (or backup) storage locations. ^ Primary location is the memory of the specific module. ^ First backup location is the VID block memory of the Powertrain Control Module (PCM). ^ Second backup is the As-Built Data Center. During PMI, the scan tool will attempt to extract the module configuration information from the module to be changed. If this is unsuccessful, the scan tool will use the first backup and attempt to extract the module configuration information from the VID block in the PCM. If this also fails, the scan tool will display instructions to contact the As-Built Data Center. This is the only time the As-Built Data Center should be contacted. Programmable Module Installation (PMI) NOTE: If the powertrain control module (PCM) needs to have a powertrain calibration flash programmed, refer to Computers and Control Systems. Make sure to use the flash cable when programming calibrations or running a PMI routine on the PCM. The PMI configuration method is used when a new programmable module is to be installed. During the PMI routine the scan tool attempts to gather two pieces of information: ^ Option content information from the old module. (module configuration and customer preference settings) ^ The Vehicle Identification Number (VIN) from the PCM. During PMI the scan tool first looks to the PCM for the VIN number of the vehicle. Once the VIN is retrieved the scan tool will carry out a self-test of the suspect module to determine if the module has been configured. ^ If DTC B2477 is present the module does not contain complete configuration information. The PMI routine will then halt and give instructions on how to proceed. ^ If DTC B2477 is not present the module will allow the scan tool to retrieve its option content information. The scan tool will then store the option content information and the VIN. The scan tool can store the combined option content information and VIN for only one module at a time. Once information is stored, the scan tool cannot be used to retrieve any other option content information without erasing the previous option content information. Make sure the new module is onhand for installation before retrieving option content information data from the old module. After the new module is installed, use the scan tool to restore the option content information into the new module. Vehicle Identification (VID) Block NOTE: ^ If the Powertrain Control Module (PCM) needs to have a powertrain calibration flash programmed, refer to Computers and Control Systems. Make sure to use the fash cable when programming calibrations or running a PMI routine on the PCM. ^ When carrying out a PMI routine on any non-PCM module, use the OBDII cable. ^ Flash programming powertrain calibrations onto the PCM is different than PMI. It has no effect on the backup data in the VID block memory area of the PCM. The PCM contains a memory area called a Vehicle Identification (VID) block. A portion of the VID block is used to store the backup data for each programmable module on the vehicle. The VID block is the first backup of information when using the PMI configuration method. If the scan tool cannot retrieve option content information from the suspect module, the scan tool will attempt to extract backup information from the VID block of the PCM. The VID block is not related to or effected by the powertrain calibration information stored in the PCM. If a new powertrain calibration has been flashed onto the PCM, the VID block will not be affected. If using the PMI routine to install a new PCM, the scan tool will reprogram only VID information. The engine calibration information may still need to be flashed. For more information, refer to Computers and Control Systems for flash programming information. As-Built Data Center The As-Built Data Center keeps a record of the vehicle configuration in a database retrievable using the VIN. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center will always reflect the original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the scan tool. Customer Preference Items This method is used to enable or disable module-controlled items or systems to suit the preference of the customer. Not all features controlled by the module are listed in this configuration method. Refer to the Module Configuration Index for a list of features per module. If an item is changed using the customer preference items configuration method, the changed information will not be stored in the PCM VID block. The VID block will retain the original settings as they were recorded when the vehicle left the factory. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3413 Manufacturer Options This method of configuration is used on modules that do not support PMI. This method is used to enable or disable module-configurable features to set module option content of the vehicle and the preference of the customer. Refer to the Module Configuration Index for a list of features per module. If an item is changed using the manufacturer options configuration method, the changed information will not be stored in the PCM VID block. The VID block will retain the original settings as they were recorded when the vehicle left the factory. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Multiplex Communication Network: Testing and Inspection Module Communications Network Initial Inspection 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(30A) ^ Wiring harness ^ Loose or Corroded connections ^ Anti-lock brake control module ^ Electronic automatic temperature control (EATC) module ^ Passive anti-theft system (PATS) nodule ^ Natural gas vehicle module (NGVM) ^ Electric crash sensor (ECS) ^ Driver door module (DDM) ^ Lighting control module (LCM) ^ Powertrain control module (PCM) 3. If the concern remains after the inspection, connect the scan tool to the DLC located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool 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 the scan tool still does not communicate with the vehicle, GO to Symptom Chart. See: Diagnosis By Symptom 4. GO to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3416 PC1 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. Test A: ABS Control Module Does Not Respond to the Scan Tool Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3417 A1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3418 A2 - A3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3419 A4 - A5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3420 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3421 C1 - C3 Test D: NGVM Does Not Respond To The Diagnostic Tool Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3422 D1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3423 D2 - D3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3424 D4 - D5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3425 E1 - E2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3426 E3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3427 F1 - F2 Test G: PCM Module Does Not Respond To The Diagnostic Tool Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3428 G1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3429 G2 - G3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3430 G4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3431 G5 - G6 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3432 G7 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3433 H1 - H2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3434 H3 Test I: No ISO 9141 Network Communication Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3435 I1 - I2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3436 I3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3437 I4 - I5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3438 I6 Test J: No SCP Network Communication Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3439 J1 - J2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3440 J3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3441 J4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3442 J5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3443 J6 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3444 J7 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3445 J8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3446 J9 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3447 J10 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3448 J11 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3449 J12 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3450 J13 - J14 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3451 J15 - J16 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3452 J17 - J18 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3453 J19 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3454 J20 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3455 J21 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3456 J22 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3457 K1 - K2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3458 K3 - K4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3459 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3460 Multiplex Communication Network: Testing and Inspection Module Configuration Inspection and Verification 1. Visually inspect for obvious signs of electrical damage. Refer to the chart: VISUAL INSPECTION CHART Electrical ^ Damaged wiring harness ^ Loose or corroded connectors ^ Anti-lock brake control (ABS) 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) 2. If the concern remains after inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from scan tool menu. If scan tool 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 scan tool still will not communicate with the vehicle, refer to Module Communications Network (Information Bus). 3. Refer to the Symptom Chart. See: Diagnosis By Symptom General Procedures NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting customer preference items and supports the specific item to be configured in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the customer preference item to be programmed. Refer to the Module Configuration Index. See: Scan Tool Testing/Module Configuration Index 3. Select Customer Preference Items on the scan tool. 4. Select Module Option Content. 5. Select the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the customer preference. Module Configuration Index NOTE: Do not contact the As-Built Data Center unless the scan tool instructs you to do so. The scan tool will not allow you to use as-built data information unless the scan tool first prompts you for the As-Built Data Center information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3461 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3462 A1 - A3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3463 Multiplex Communication Network: Service and Repair WIRING REPAIRS Heat Gun SPECIAL SERVICE TOOL(S) 1. Disconnect the battery ground cable. For additional information, refer to Battery. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3464 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Multiplex Communication Network: Tools and Equipment Heat Gun Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 3467 Multiplex Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3474 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3475 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3489 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3490 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3491 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3492 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3493 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3494 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3495 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3496 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3497 ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3498 ^ 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) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3499 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3500 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3501 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3502 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3503 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3504 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) - Front 41 Nm Heated Oxygen Sensor (HO2S) - Rear 41 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3505 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3509 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3510 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3511 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3512 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3513 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3523 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3524 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the powertrain control module used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the powertrain control module used to calculate catalytic converter integrity. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front Heated Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Service Tool(s) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the right side Heated Oxygen Sensor (HO2S) electrical connector. 3. Disconnect the left side HO2S electrical connector. 4. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 5. Using the special tool, remove the HO2S. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 3527 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 3528 Heated Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Service Tool(S) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 4. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9LA94-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Page 3529 Heated Oxygen Sensor: Tools and Equipment EGO Sensor Wrench EGO Sensor Wrench Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3536 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > 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 3542 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > 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 3543 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3544 Powertrain Control Module: Specifications Powertrain control module electrical connector bolt 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3545 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3546 Powertrain Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3547 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3548 Powertrain Control Module: Description and Operation The PCM carries out the following functions: ^ accepts input from various engine sensors to complete the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3549 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and remove the Powertrain Control Module (PCM) electrical connector. 3. Remove the PCM cover nuts. 4. Remove the PCM cover. 5. Remove the under dash sight cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3552 6. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3553 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3557 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3558 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3563 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3564 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3565 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 3566 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3570 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3571 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3572 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 > Page 3579 Coolant Temperature Sensor/Switch (For Computer): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3580 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature The Engine Coolant Temperature (ECT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3581 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 3582 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3586 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3587 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3590 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3591 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Sensor 27 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3595 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3596 Engine Temperature Sensor: Description and Operation The Cylinderhead Temperature Sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the powertrain control module indicating the cylinder head temperature. If the temperature exceeds approximately 121°C (250°F), the powertrain control module disables four fuel injectors at a time. The powertrain control module will alternate which fuel injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds approximately 166°C (3300 F), the powertrain control module disables all of the fuel injectors until the engine temperature drops below approximately 154°C (310°F). ^ If the engine reaches critical temperature, the following happens: The coolant temperature gauge pointer will read fully hot at approximately 121 CC (250°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3597 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications Fuel Level Sensor: Specifications Fuel Level Sensor 4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Specifications > Page 3601 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information Fuel Tank Pressure Sensor: Technician Safety Information WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Technician Safety Information > Page 3610 Fuel Tank Pressure Sensor: Vehicle Damage Warnings CAUTION: ^ The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3611 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. The fuel tank pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. ^ is located in the fuel tank and is serviced as a separate item. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3612 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Partially drain and lower the fuel tank. For additional information, refer to Fuel Tank/Service and Repair. See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair CAUTION: The fuel tank pressure sensor electrical connector must be disconnected before the fuel tank removal. Failure to do so can cause damage to the fuel tank or fuel tank pressure sensor. 3. Push down and rotate the fuel tank pressure sensor counterclockwise to remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor Intake Air Temperature Sensor: Locations Ambient Air Temperature Sensor Center front of vehicle, on front of upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Ambient Air Temperature Sensor > Page 3617 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3618 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 3619 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3633 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3634 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3635 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3636 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3637 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3638 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3639 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3640 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3641 ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3642 ^ 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) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3643 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3644 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3645 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3646 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3647 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3648 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) - Front 41 Nm Heated Oxygen Sensor (HO2S) - Rear 41 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3649 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Heated 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3667 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3668 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor The Heated Oxygen Sensor (HO2S) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the powertrain control module used to calculate fuel delivery. The rear HO2S: ^ monitors oxygen content after it flows through the catalytic converter. ^ provides a voltage to the powertrain control module used to calculate catalytic converter integrity. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front Heated Oxygen Sensor: Service and Repair Front EGO Sensor Wrench Special Service Tool(s) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the right side Heated Oxygen Sensor (HO2S) electrical connector. 3. Disconnect the left side HO2S electrical connector. 4. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 5. Using the special tool, remove the HO2S. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 3671 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Front > Page 3672 Heated Oxygen Sensor: Service and Repair Rear EGO Sensor Wrench Special Service Tool(S) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 4. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9LA94-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Service and Repair > Page 3673 Heated Oxygen Sensor: Tools and Equipment EGO Sensor Wrench EGO Sensor Wrench Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3680 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3684 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3685 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3689 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3690 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3691 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3692 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3693 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 3699 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 VIN W (2000)) 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 3700 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 VIN W (2000)) 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 3701 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 VIN W (2000)) 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 3702 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3703 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3704 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 VIN W (2000)) 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 3705 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 VIN W (2000)) 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 3706 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 VIN W (2000)) 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 3707 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 VIN W (2000)) 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 3708 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 VIN W (2000)) 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 3709 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 VIN W (2000)) 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 3710 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3711 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3712 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3713 Vehicle Speed Sensor: Electrical Diagrams Diagram 64-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3714 Diagram 64-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3715 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3719 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3720 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3724 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3725 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3726 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3727 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3728 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3736 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3737 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3738 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3740 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Vehicle Speed Sensor: Electrical Diagrams Diagram 64-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 Diagram 64-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3750 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3756 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3757 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3758 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3759 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3760 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3761 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3762 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3763 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3764 ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3765 ^ 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) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3766 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3767 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3768 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3769 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3770 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3771 Catalytic Converter: Specifications Three Way Catalytic Converter to Exhaust Manifold Nuts 25 - 33 ft.lb Three Way Catalytic Converter to Inlet Pipe Flange Nuts 25 - 33 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3772 Catalytic Converter: Description and Operation Overview Generic Catalyst and Exhaust System The Catalytic Converter and Exhaust Systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides Of Nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either Platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can br brst accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3773 the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the H02S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the H02S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3774 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 TWC. - Remove the nuts, bolts, damper and gasket. - Remove the TWC. Installation 1. Position the Three Way Catalytic Converters (TWC) and install the two nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3775 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Evaporative Emission Canister Purge Nuts 7.6 - 10.4 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3780 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3781 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve EVAP Canister Purge Valve Focus, Escort, Taurus/Sable, Mustang, and LS6/LS8 (EVAP Canister Purge Valve) The EVAP canister purge valve is the part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3782 Canister Purge Control Valve: Service and Repair REMOVAL 1. Disconnect the connector. 2. Disconnect the evaporative emission return tube. 3. Disconnect the evaporative emission test port. 4. Remove the vacuum hose. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3783 5. Remove the two nuts and the evaporative emission canister purge valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations Evaporative Check Valve: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations > Page 3787 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations > Page 3788 Evaporative Check Valve: Service Precautions CAUTION: ^ The fuel vapor control valve tube assembly and the fuel vapor vent valve are removed as one piece. Do not attempt to separate. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations > Page 3789 Evaporative Check Valve: Description and Operation The fuel vapor control valve tube assembly: ^ consists of the fuel vapor control valve and fuel vapor vent valve. ^ prevents suspended liquid fuel from being drawn into the evaporative emission canister along with the fuel vapors. ^ returns the liquid to the fuel tank. ^ includes a fresh air transfer tube routing fresh air between the canister vent solenoid hose and the fuel tank filler pipe assembly. ^ requires two grommets to seal the fuel vapor control valve and fuel vapor vent valve to the fuel tank. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations > Page 3790 Evaporative Check Valve: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. Fuel Tank/Service and Repair. See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair 2. Remove the fuel vapor control valve tube assembly. ^ Apply upward pressure on the fuel vapor vent valve. ^ Remove the fuel vapor control valve tube assembly. CAUTION: The fuel vapor control valve tube assembly and the fuel vapor vent valve are removed as one piece. Do not attempt to separate. 3. Remove the fuel vapor control valve. ^ Push down and rotate counterclockwise. ^ Remove the fuel vapor control valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-Ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144-B. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Technical Service Bulletin # 02B02 Date: 030301 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3799 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3800 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3801 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3802 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3803 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 VIN W (2000)) 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 3804 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 VIN W (2000)) 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 3805 ^ 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 VIN W (2000)) 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 3806 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 VIN W (2000)) 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 3807 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 VIN W (2000)) 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 3808 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 VIN W (2000)) 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 3809 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 VIN W (2000)) 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 3810 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3811 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3812 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3813 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3814 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3815 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 VIN W (2000)) 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 3816 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 VIN W (2000)) 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 3817 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 VIN W (2000)) 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 3818 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 VIN W (2000)) 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 3819 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3820 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3821 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3822 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3823 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3824 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3825 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3826 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 3832 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3833 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3834 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3835 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3836 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 VIN W (2000)) 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 3837 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 VIN W (2000)) 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 3838 ^ 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 VIN W (2000)) 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 3839 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 VIN W (2000)) 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 3840 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 VIN W (2000)) 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 3841 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 VIN W (2000)) 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 3842 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 VIN W (2000)) 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 3843 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3844 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3845 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3846 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3847 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3848 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 VIN W (2000)) 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 3849 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 VIN W (2000)) 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 3850 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 VIN W (2000)) 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 3851 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 VIN W (2000)) 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 3852 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3853 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3854 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3855 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3856 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3857 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3858 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 3859 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Page 3860 Evaporative Emission Control Canister: Specifications Evaporative emissions canister bolts and nuts 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Page 3861 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Page 3862 Evaporative Emission Control Canister: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Page 3863 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. For additional information refer to Maintenance/Service and Repair. 3. Disconnect the electrical connector. 4. Separate the canister vent solenoid hose assembly. 5. Separate the fuel vapor hose assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Page 3864 6. Remove the Evaporative (EVAP) Emissions canister with bracket assembly. ^ Remove the bolts. ^ Remove the nuts. 7. Disconnect the fuel vapor hose assembly elbow at the EVAP canister. 8. Remove the canister vent solenoid from the EVAP canister. 9. Remove the EVAP canister. INSTALLATION 1. To install, reverse the removal procedure. ^ leak test the system. For additional information, refer to Evaporative Emission System leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins > Page 3865 Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service Precautions Evaporative Emissions Hose: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service Precautions > Page 3869 Evaporative Emissions Hose: Service and Repair DISCONNECT 1. Disconnect the battery. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations > Page 3873 Evaporative System Service Port: Description and Operation The evaporative emission (EVAP) test port: ^ is used to connect the Evaporative Emission System Leak Tester to the EVAP system. ^ is located on the EVAP canister purge outlet tube near the EVAP canister purge valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations > Page 3874 Evaporative System Service Port: Service and Repair REMOVAL 1. Disconnect the evaporative emission test port at the evaporative (EVAP) emission canister purge valve. 2. Remove the EVAP emission test port by disconnecting at the EVAP canister purge outlet tube. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3878 Leak Detection Valve: Service Precautions CAUTION: ^ The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3879 Leak Detection Valve: Description and Operation Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. The canister vent solenoid: ^ is normally open. ^ seals the EVAP system for the inspection and maintenance (I/M 240) test and OBD II leak and pressure tests. ^ is mounted to the evaporative emission canister. ^ is repaired as a separate item. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid Closing Procedure Leak Detection Valve: Service and Repair Canister Vent Solenoid Closing Procedure Worldwide Diagnostic System (WDS) Special Service Tool(s) CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. 1. Connect the scan tool and select the output test mode. 2. Select the Fuel Tank Pressure and the Volts Parameter Identification for monitoring. 3. Select the ALL OFF mode. 4. Close the canister vent solenoid by pushing the START button on the scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid Closing Procedure > Page 3882 Leak Detection Valve: Service and Repair Removal and Installation REMOVAL 1. Remove the evaporative emission (EVAP) canister and bracket assembly. For additional information, refer to Evaporative Emission Canister. 2. Disconnect the canister vent solenoid vent hose. 3. Remove the canister vent solenoid. INSTALLATION 4. To install, reverse the removal procedure. ^ Carry out the Leak Test. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the Evaporative Emission Repair Verification Drive Cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate the O-ring seal with MERPOL(R) O-Ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144B. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Page 3883 Worldwide Diagnostic System (WDS) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation On-Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System Focus, Escort, and Contour/Mystique/Cougar (ORVR EVAP System) LS6/LS8 (ORVR EVAP System) Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Page 3887 The basic elements forming the ORVR system operation are as follows when fuel is dispensed: 1. The fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank, while liquid is entering the fuel tank (liquid in the one inch diameter tube blocks vapors from rushing back up the fuel filler pipe). 2. A fuel vapor control valve controls the flow of vapors out of the fuel tank (valve closes when liquid level reaches a height associated with the fuel tank usable capacity). This valve accomplishes the following: a. Limits the total amount of fuel that can be dispensed into the fuel tank. b. Prevents liquid gasoline from exiting the fuel tank when submerged (and also when tipped well beyond a horizontal plane as part of the vehicle roll-over protection in road accidents). c. Minimizes vapor flow resistance during anticipated refueling conditions. 3. Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the fuel tank vapors (displaced by the incoming liquid) to the EVAP canister. 4. A check valve in the bottom of the fuel filler pipe prevents liquid from rushing back up the fuel filler pipe during the liquid flow variations associated with the filler nozzle shut-off. Between refueling events, the EVAP canister is purged with fresh air so that it may be used again to store vapors accumulated engine soaks or subsequent refueling events. The vapors drawn off of the carbon in the EVAP canister are consumed in the engine. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations Component Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3892 EGR Backpressure Transducer: 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 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 VIN W (2000)) 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 vent Solenoid-to-acceleration bracket 7.6-10.4 Nm EGR Vacuum Regulator Solenoid Nuts 8-12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3896 Component Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 3897 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid Graph EGR Vacuum Regulator Solenoid Data The EGR vacuum regulator solenoid is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR tube (NGV) 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3901 Component Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3902 EGR Tube: Description and Operation Orifice Tube Assembly Orifice Tube Assembly The orifice tube assembly is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3903 EGR Tube: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3904 5. Remove the nut at the EGR valve. 6. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3905 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3909 EGR Valve: Description and Operation Exhaust Gas Recirculation Valve Exhaust Gas Recirculation Valve Exhaust Gas Recirculation Valve Graph The EGR valve in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Differential Pressure Feedback EGR Valve EGR Valve: Service and Repair Differential Pressure Feedback EGR Valve 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Differential Pressure Feedback EGR Valve > Page 3912 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Differential Pressure Feedback EGR Valve > Page 3913 EGR Valve: Service and Repair EGR Valve 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Differential Pressure Feedback EGR Valve > Page 3914 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Differential Pressure Feedback EGR Valve > Page 3915 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3919 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Locations Component Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Locations > Page 3924 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Locations > Page 3925 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Component Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3929 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 PVC valve from the crankcase vent connector and hose. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3930 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3935 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 3944 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3948 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3949 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 790 - 815 RPM Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3956 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3957 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 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3960 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 3961 Accelerator Pedal: Service and Repair 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 VIN W (2000)) 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 element. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3969 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3970 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3971 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3972 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diagnostic Connector - Fuel Pump > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3984 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3985 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3986 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3987 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3988 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3994 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3995 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3996 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3997 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3998 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 3999 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4000 Fuel Filler Cap: Description and Operation Fuel Filler Cap Fuel Filler Cap The fuel filler cap is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. The fuel tank filler cap: ^ relieves system pressure above 14 kPa (56.21 inches H20). ^ relieves system vacuum below 3.8 kpa (15.26 inches H20). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4005 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(s) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ this will drain some fuel out of the system. Place the fuel in a suitable container. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4006 EFI/CFI Fuel Pressure Gauge Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions Fuel Injector Wiring Harness: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4011 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. For additional information, refer to Steering. 2. Remove the air cleaner outlet tube. 3. Disconnect the battery ground cable. For additional information, refer to Battery. 4. Remove the mounting arm and pivot shaft. For additional information, refer to Wiper and Washer Systems. 5. Disconnect the: ^ idle air control valve. ^ throttle position sensor. 6. Disconnect the eight ignition coils. 7. Disconnect the eight fuel injector electrical connectors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4012 8. Disconnect the fuel pressure sensor. 9. Disconnect the engine bulkhead connectors. 10. Disconnect the radio ignition interference capacitor. 11. Disconnect the LH heated oxygen sensor connector and the transmission electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4013 12. Disconnect the RH heated oxygen sensor connector. 13. Disconnect the EGR transducer. 14. Disconnect the evaporative emission canister purge valve. 15. Disconnect the EGR vacuum regulator solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4014 16. Disconnect the connector. 17. Disconnect the A/C cycling switch. 18. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 19. Disconnect the crankshaft position sensor. 20. Disconnect the A/C compressor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4015 21. Disconnect the: ^ engine oil pressure sensor. ^ power steering pressure switch. 22. Lower the vehicle. 23. 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. For additional information, refer to Maintenance/Service and Repair. 3. Connect the: ^ engine oil pressure sensor. ^ power steering pressure switch. 4. Connect the A/C compressor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4016 5. Connect the crankshaft position sensor. 6. Install the power steering pump. For additional information, refer to Steering. 7. Lower the vehicle. 8. Connect the A/C cycling switch. 9. Connect the connector. 10. Connect the EGR vacuum regulator solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4017 11. Connect the evaporative emission canister purge valve. 12. Connect the EGR transducer. 13. Connect the RH heated oxygen sensor connector. 14. Connect the LH heated oxygen sensor connector and the transmission electrical connectors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4018 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. 19. Connect the fuel temperature sensor connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4019 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. For additional information, refer to Wiper and Washer Systems. 24. Connect the battery ground cable. 25. Install the air cleaner outlet tube. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information Fuel Line Coupler: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information > Page 4024 Fuel Line Coupler: Vehicle Damage Warnings CAUTION: ^ Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting Fuel Line Coupler: Service and Repair Hairpin Clip Fitting DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. For additional information, refer to Pressure Relief. 2. Remove the shipping tab by bending it downward. 3. Spread the hairpin Clip legs and push the clip into the fitting. 4. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-G to the male tube end. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4027 3. Insert the hairpin clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube in the fitting and push them together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4028 Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Disconnect Tool SPECIAL SERVICE TOOL(s) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. For additional information, refer to Pressure Relief. 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push into the fitting. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4029 4. Separate the fittings. ^ Inspect for damage. ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push until a click is heard. NOTE: Lubricate the tube end with clean engine Oil meeting Ford specification WSS-M2C153-G to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4030 Fuel Line Coupler: Service and Repair Spring Lock Couplings Special Tool(s) SPECIAL SERVICE TOOL(s) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. For additional information, refer to Pressure Relief. 2. Remove the fuel tube clip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4031 3. Install the Disconnect Tool. 4. Close and push the Disconnect Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Disconnect Tool. CONNECT 1. Follow the removal procedure in reverse order. ^ Inspect and clean both the coupling ends. ^ Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-G. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 4032 Fuel Line Coupler: Tools and Equipment EGO Sensor Wrench Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel pressure regulator coolant bowl screw 7 Nm 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4036 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Regulator: Technician Safety Information 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 OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Technician Safety Information > Page 4039 Fuel Pressure Regulator: Vehicle Damage Warnings 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 4040 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Fuel Pressure Regulator The fuel pressure regulator is attached to the fuel rail downstream of the fuel injectors. It regulates fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel tank. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Page 4041 Fuel Pressure Regulator: 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 OF 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. Relieve fuel pressure. 2. Remove the upper intake manifold. For additional information, refer to Engine. 3. Remove the fuel pressure regulator. 1 Disconnect the fuel pressure regulator vacuum hose. 2 Remove the snap ring. 3 Remove the fuel pressure regulator. 4. Remove and discard the fuel pressure regulator O-rings and the seal. INSTALLATION 1. To install, reverse the removal procedure. 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: Lubricate the fuel injector pockets with clean engine oil, XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-M2CI 53-G, to aid installation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations > Page 4045 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Description and Operation Fuel Pressure Pulsation Damper: Description and Operation Pulse Damper Pulse Damper The fuel rail pulse damper located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 4057 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 4078 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 4079 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 4083 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information Fuel Rail: Technician Safety Information 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 OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information > Page 4086 Fuel Rail: Vehicle Damage Warnings CAUTI0N: ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4087 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 OF 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. For additional information, refer to Battery. 2. Relieve the fuel pressure. 3. Disconnect the fuel lines. 4. Remove the throttle body. For additional information, refer to Throttle Body. 5. Remove the EGR valve to exhaust manifold tube. For additional information, refer to Exhaust Gas Recirculation. 6. Remove the drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4088 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4089 15. Remove the nut-bolt and the wiring bracket. 16. Disconnect the eight fuel injector electrical connectors. 17. Disconnect the crankcase ventilation tube and position out of the way. 18. Disconnect the vacuum line. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4090 19. Disconnect the vacuum line from the evaporative emission (EVAP) canister purge valve. 20. Disconnect the EGR vacuum regulator solenoid. 21. Remove the bolt and the stud. 22. Remove the crash bracket. 23. Remove the studs. 24. 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. CAUTI0N: 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. 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. 7. Connect the FOR vacuum regulator solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4091 8. Connect the vacuum line to the evaporative emission canister purge valve. 9. Connect the vacuum line. 10. Connect the crankcase ventilation tube. 11. Connect the eight fuel injector electrical connectors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4092 12. Connect the vacuum lines. 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. 15. Clip the accelerator cable and the speed control actuator cable to the two crash brackets. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4093 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. 20. Connect the fuel pressure sensor connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4094 21. Connect the fuel temperature sensor connector. 22. Install the drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 23. Install the EGR valve to exhaust manifold tube. For additional information, refer to Exhaust Gas Recirculation. 24. Install the throttle body. For additional information, refer to the Throttle Body. 25. Connect the fuel lines. 26. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation Technical Service Bulletin # 00S11 Date: 000701 Recall - Fuel Line Retainer Clip Installation 00S11 SAFETY RECALL Certain 2000 Model Year Windstars - Fuel-Line Retention ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4103 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4104 ^ 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. 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 vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES 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 in the table. ORDER INFORMATION DOR/COR DOR/COR number 50167 identities parts ordered for this campaign through the Recall Hotline (1-800-325-5621) for the first 30 days. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4105 SERVICE PROCEDURE 1. Raise and support the vehicle. CAUTION Orientation of the fuel line clips is critical. The prongs on each clip should face away from the fuel tank. Do not cover the blue release tab of the fuel fittings with the clips. 2. Install a fuel line clip to the fuel supply line and return line fittings located in front of the fuel tank as follows. ^ Snap the lower end of a fuel line clip onto each of the fuel lines, then slide the legs of each clip into the end of the fuel line fitting. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4106 ^ Snap the top end of each fuel line clip onto the fuel line fitting. The locating fingers of the clip should be seated in the groove on the fitting. See Figure 2. ^ Install the tether clip to the fuel line. See Figure 2. 3. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4107 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4108 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation Technical Service Bulletin # 00S11 Date: 000701 Recall - Fuel Line Retainer Clip Installation 00S11 SAFETY RECALL Certain 2000 Model Year Windstars - Fuel-Line Retention ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4114 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4115 ^ 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. 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 vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES 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 in the table. ORDER INFORMATION DOR/COR DOR/COR number 50167 identities parts ordered for this campaign through the Recall Hotline (1-800-325-5621) for the first 30 days. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4116 SERVICE PROCEDURE 1. Raise and support the vehicle. CAUTION Orientation of the fuel line clips is critical. The prongs on each clip should face away from the fuel tank. Do not cover the blue release tab of the fuel fittings with the clips. 2. Install a fuel line clip to the fuel supply line and return line fittings located in front of the fuel tank as follows. ^ Snap the lower end of a fuel line clip onto each of the fuel lines, then slide the legs of each clip into the end of the fuel line fitting. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4117 ^ Snap the top end of each fuel line clip onto the fuel line fitting. The locating fingers of the clip should be seated in the groove on the fitting. See Figure 2. ^ Install the tether clip to the fuel line. See Figure 2. 3. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4118 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Return Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4119 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation Technical Service Bulletin # 00S11 Date: 000701 Recall - Fuel Line Retainer Clip Installation 00S11 SAFETY RECALL Certain 2000 Model Year Windstars - Fuel-Line Retention ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4128 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4129 ^ 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. 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 vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES 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 in the table. ORDER INFORMATION DOR/COR DOR/COR number 50167 identities parts ordered for this campaign through the Recall Hotline (1-800-325-5621) for the first 30 days. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4130 SERVICE PROCEDURE 1. Raise and support the vehicle. CAUTION Orientation of the fuel line clips is critical. The prongs on each clip should face away from the fuel tank. Do not cover the blue release tab of the fuel fittings with the clips. 2. Install a fuel line clip to the fuel supply line and return line fittings located in front of the fuel tank as follows. ^ Snap the lower end of a fuel line clip onto each of the fuel lines, then slide the legs of each clip into the end of the fuel line fitting. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4131 ^ Snap the top end of each fuel line clip onto the fuel line fitting. The locating fingers of the clip should be seated in the groove on the fitting. See Figure 2. ^ Install the tether clip to the fuel line. See Figure 2. 3. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4132 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4133 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation Technical Service Bulletin # 00S11 Date: 000701 Recall - Fuel Line Retainer Clip Installation 00S11 SAFETY RECALL Certain 2000 Model Year Windstars - Fuel-Line Retention ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4139 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4140 ^ 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. 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 vehicles are not approved for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES 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 in the table. ORDER INFORMATION DOR/COR DOR/COR number 50167 identities parts ordered for this campaign through the Recall Hotline (1-800-325-5621) for the first 30 days. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4141 SERVICE PROCEDURE 1. Raise and support the vehicle. CAUTION Orientation of the fuel line clips is critical. The prongs on each clip should face away from the fuel tank. Do not cover the blue release tab of the fuel fittings with the clips. 2. Install a fuel line clip to the fuel supply line and return line fittings located in front of the fuel tank as follows. ^ Snap the lower end of a fuel line clip onto each of the fuel lines, then slide the legs of each clip into the end of the fuel line fitting. See Figure 1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4142 ^ Snap the top end of each fuel line clip onto the fuel line fitting. The locating fingers of the clip should be seated in the groove on the fitting. See Figure 2. ^ Install the tether clip to the fuel line. See Figure 2. 3. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4143 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 00S11 > Jul > 00 > Recall - Fuel Line Retainer Clip Installation > Page 4144 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Page 4145 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4155 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4156 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4157 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4158 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4159 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4165 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4166 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4167 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4168 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4169 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4170 Fuel Filler Hose: Specifications Fuel Tank Filler Pipe-To-Body Screws 4 Nm Fuel Tank Filler Pipe Bracket Screw 6 -7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4171 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4172 Fuel Filler Hose: Service Precautions CAUTION: ^ Do not damage retainer ring during removal or the cap may not seal. ^ The dogpoint screw has a blunt end and must be used in this application. ^ Exercise care not to damage grommet or check valve at end of pipe. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4173 Fuel Filler Hose: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Drain the fuel tank. 3. Remove the screws. CAUTION: Do not damage retainer ring during removal or the cap may not seal. 4. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 5. Remove the LH rear wheel and tire assembly. 6. Disconnect the vapor recirculation tube connector. 7. Remove the screw. CAUTION: The dogpoint screw has a blunt end and must be used in this application. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4174 8. Remove the fuel tank filler pipe. 1 Slide the fuel tank filler pipe into the tank enough to obtain clearance. 2 Rotate counterclockwise 1/2 turn and remove the fuel tank filler pipe. CAUTION: Exercise care not to damage grommet or check valve at end of pipe. NOTE: If unable to obtain sufficient clearance for removal, the tank straps may have to be loosened. INSTALLATION 1. Install the fuel tank filler pipe in the fuel tank. NOTE: Lubricate the fuel tank filler pipe end with petroleum meeting Ford specification ESW-M1C115-A or ESB-M1C99-A. 2. Install the dogpoint screw. NOTE: Screw has a blunt end and must be used in this application. 3. Install the screws. NOTE: Attach strap for cap at 4:00 o'clock position. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4175 4. Connect the vapor recirculation hose. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4184 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4185 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4186 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4187 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4188 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4194 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4195 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4196 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4197 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4198 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4205 Fuel Tank Unit: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4206 Fuel Tank Unit: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Tank. See: Fuel Tank/Service and Repair 2. Disconnect the pressure transducer connector on the top rear comer of the fuel tank. 3. Clean the area around the fuel pump mounting flange. 4. Remove the bolts and remove the fuel pump. CAUTION: The fuel pump must be handled carefully to avoid damage to the float arm and the filter. 5. Remove and discard the fuel pump mounting gasket. INSTALLATION 1. Clean the fuel pump mounting flange and the fuel tank mounting surface. 2. Install the fuel pump mounting gasket on the mounting flange. 3. Install the fuel pump. 1 Position the fuel pump in the fuel tank. 2 Install the bolts. 3 Connect the fuel pressure transducer. NOTE: Tighten fuel pump bolts in a star pattern 1-3-5; 2-4-6. 4. Install the fuel tank. For additional information, refer to Fuel Tank. See: Fuel Tank/Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service Precautions Fuel/Water Separator: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4216 Idle Air Control Valve: Description and Operation Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly with Vent/Filter Hitachi Idle Air Control (IAC) Valve Assembly with Air-Assist Injectors The Idle Air Control (IAC) valve assembly controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the AC duty cycle in order to achieve the desired rpm. On applications with air-assisted injectors, the IAC valve also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4217 NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4218 Idle Air Control Valve: Testing and Inspection Idle Air Control Valve Noise Test 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an EngineEAR probe near the IAC valve 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 IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. For further information concerning the diagnosis of this component and that system that it is a part of, please refer to Computers and Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4219 Idle Air Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Disconnect the Idle Air Control (IAC) valve electrical connector. 4. Remove the IAC valve hose. 5. Remove the IAC valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws 1.0 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4223 Inertia Fuel Shutoff Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4224 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4225 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4226 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Open the luggage compartment door. 2. Disconnect the connector from the Inertia Fuel Shutoff (IFS) switch. 3. Remove the retaining screws from the IFS switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL 1. 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: The gasoline engine is shown, the natural gas engine is similar. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 4230 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4234 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4235 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Fuel Pump Relay: 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 4257 Fuel Pump Relay: Description and Operation The Fuel Pump (FP) is a PCM output signal that is used to control the electric fuel pump. With the electronic EC power relay contacts closed, vehicle power (VPWR) is sent to the coil of the fuel pump relay. For electric fuel pump operation, the PCM grounds the FP circuit, which is connected to the coil of the fuel pump relay. This energizes the coil and closes the contacts of the relay, sending B+ through the FP PWR circuit to the electric fuel pump. When the ignition key is turned on, the electric fuel pump runs for about one second, but is then turned off by the PCM if engine rotation is not detected. For applications with two speed fuel pumps, a normally closed low speed fuel pump relay (Figure 48) is wired into the fuel pump ground circuit. With the low speed fuel pump relay contacts in the normally closed position, there is no extra resistance in the ground circuit for high speed operation. For low speed fuel pump operation, the PCM will ground the Low Fuel Pump (LFP) circuit, which opens the relay contacts. With the relay contacts open, the fuel pump ground circuit now passes through a resistor that is wired into the circuit. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 4258 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4262 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4263 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 4268 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 4269 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 4270 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Locations > Page 4271 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Disconnect the air cleaner outlet tube. 4. Remove the four bolts and the MAF sensor. CAUTION: Do not tamper with the MAF sensing elements located in the airflow bypass. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and replaced as a unit. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Inertia Fuel Shutoff Switch Screws 1.0 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4278 Inertia Fuel Shutoff Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4279 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4280 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications > Page 4281 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Open the luggage compartment door. 2. Disconnect the connector from the Inertia Fuel Shutoff (IFS) switch. 3. Remove the retaining screws from the IFS switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4285 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4286 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle body bolts (gasoline 71 - 106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4290 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information Throttle Body: Technician Safety Information 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 4293 Throttle Body: Vehicle Damage Warnings CAUTION: The throttle body bore and plate area have a special coating and cannot be cleaned. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4294 Throttle Body: Description and Operation Throttle Body Housing The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4295 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 is similar. 1. Remove the air cleaner outlet tube. 2. Disconnect the throttle position 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4296 5. Remove the four bolts and the throttle body. NOTE: Discard the throttle body gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4301 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 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4304 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable Throttle Cable/Linkage: Service and Repair Cable 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4307 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 vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4308 Throttle Cable/Linkage: 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. For additional information, refer to Cruise Control. 5. Remove the spring. 6. Remove the nuts and remove the EGR vent solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4309 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Top center rear of engine, left hand side of throttle body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4313 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (TP) sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor ^ sends the powertrain control module a signal indicating the throttle plate angle. ^ is the main input to the powertrain control module from the driver. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4314 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the engine appearance cover. 3. Remove the throttle position sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation Variable Induction Control Valve: Description and Operation Intake Manifold Tuning (IMT) Valve Intake Manifold Tuning Valve (IMTV) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4319 Intake Air System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4320 2.5L Cougar Intake Air System 3.0L LS6 Intake Air System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4321 3.8L Windstar Intake Air System Intake Air System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4322 4.6L E/F-Series Intake Air System 5.4L (4V) Intake Air System The Intake Manifold Tuning (IMT) valve is a motorized actuated unit mounted directly to the intake manifold. The IMT valve actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4323 The IMT valve motorized unit will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMT valve system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMT valve. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4328 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4336 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4337 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4338 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4342 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4343 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4346 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4347 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4352 procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4353 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4354 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4355 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4356 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4357 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Mechanical Specifications Ignition Coil: Mechanical Specifications ignition coil bolts 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4360 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil On Plug (COP) Ignition Coil: Description and Operation Coil On Plug (COP) Coil On Plug Coil On Plug The Coil On Plug (COP) ignition operates similar to standard coil pack ignition except each plug has one coil per plug. COP has three different modes of operation: engine crank, engine running, and CMP Failure Mode Effects Management (FMEM). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil On Plug (COP) > Page 4363 Ignition Coil: Description and Operation Coil Pack Coil Pack Example: Six-Tower Coil Pack A coil in a coil pack is turned on (for example is coil charging) by the PCM, and is turned off when firing two spark plugs at once. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. The ignition coils are triggered by the powertrain control module in pairs (cylinders 1 and 4 and cylinders 2 and 3) sending one ignition spark to the firing cylinder and one ignition spark to the corresponding cylinder on the exhaust stroke. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 4364 Ignition Coil: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the electrical connector from the ignition coil. 3. Remove the bolt. 4. Remove the ignition coil. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4372 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4373 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4374 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4378 Crankshaft Position Sensor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4379 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4382 Crankshaft Position Sensor: Description and Operation Engine Ignition The crankshaft position sensor: ^ is a variable reluctance sensor. ^ provides base timing and crankshaft speed information to the powertrain control module (PCM). ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. Refer to Service and Repair for Removal and Installation of the crankshaft position sensor. See: Service and Repair The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. ^ sends the PCM signals to indicate engine rpm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4383 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 3. Remove the Crankshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 4389 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4390 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 VIN W (2000)) 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 4391 ^ 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 VIN W (2000)) 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 4392 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 VIN W (2000)) 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 4393 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Installation Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4396 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Installation 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. 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4397 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. Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4398 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. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4399 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 4407 Spark Plug: Specifications Spark plug gap 1.32-1.42 mm Spark Plugs 20 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4408 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4409 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ............................................................... AWSF-32P Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4410 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4411 Spark Plug: Service and Repair REMOVAL 1. Remove the ignition coil. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4412 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4413 ^ 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. 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. 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 EPC solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4420 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the EPC solenoid. - Connect the TCC. - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4424 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. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4438 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4444 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 VIN W (2000)) 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 VIN W (2000)) 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 4448 Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4449 Transmission Mode Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4453 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4454 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4455 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4456 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4457 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4461 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4462 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON, DTC's P0350/P0360 Set Article No. 01-1-6 01/22/01 ^ DIAGNOSTIC TROUBLE CODES (DTCS) - P0350-P0360 COIL DTCS STORED IN MEMORY ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - COIL ON PLUG APPLICATIONS ONLY ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY - COIL ON PLUG APPLICATIONS ONLY ^ ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY COIL ON PLUG APPLICATIONS ONLY FORD: 2000 CROWN VICTORIA, ECONOLINE, EXCURSION, EXPEDITION, F SUPER DUTY, F-150 LINCOLN: 2000 LS, TOWN CAR, NAVIGATOR MERCURY: 2000 GRAND MARQUIS ISSUE Some 2000 Coil-On-Plug applications may produce P0350 through P0360 coil Diagnostic Trouble Codes (DTCS), a check engine light, and rough idle. This may be caused by the Powertrain Control Module (PCM) calibration. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4471 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4472 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4473 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4474 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4475 ACTION Perform normal diagnostics. If normal diagnostics cannot pinpoint the condition and no other concerns are found, reprogram the PCM using the Worldwide Diagnostic System (WDS) or New Generation Star (NGS) Tester. Refer to the PCM Calibration Information Chart as shown. 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 And Emissions Warranty Coverage DEALER CODING Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4476 OASIS CODES: 206000, 608000, 608400, 609000, 609400, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 4482 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 VIN W (2000)) 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 4483 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 VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON, DTC's P0350/P0360 Set Article No. 01-1-6 01/22/01 ^ DIAGNOSTIC TROUBLE CODES (DTCS) - P0350-P0360 COIL DTCS STORED IN MEMORY ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - COIL ON PLUG APPLICATIONS ONLY ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY - COIL ON PLUG APPLICATIONS ONLY ^ ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY COIL ON PLUG APPLICATIONS ONLY FORD: 2000 CROWN VICTORIA, ECONOLINE, EXCURSION, EXPEDITION, F SUPER DUTY, F-150 LINCOLN: 2000 LS, TOWN CAR, NAVIGATOR MERCURY: 2000 GRAND MARQUIS ISSUE Some 2000 Coil-On-Plug applications may produce P0350 through P0360 coil Diagnostic Trouble Codes (DTCS), a check engine light, and rough idle. This may be caused by the Powertrain Control Module (PCM) calibration. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4488 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4489 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4490 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4491 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4492 ACTION Perform normal diagnostics. If normal diagnostics cannot pinpoint the condition and no other concerns are found, reprogram the PCM using the Worldwide Diagnostic System (WDS) or New Generation Star (NGS) Tester. Refer to the PCM Calibration Information Chart as shown. 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 And Emissions Warranty Coverage DEALER CODING Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 4493 OASIS CODES: 206000, 608000, 608400, 609000, 609400, 698298 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 4499 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 VIN W (2000)) 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 4500 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. 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. 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 EPC solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4507 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the EPC solenoid. - Connect the TCC. - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4511 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. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. 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. 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 EPC solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4520 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the EPC solenoid. - Connect the TCC. - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4524 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. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator: Service and Repair 1-2 Special Tools Removal 1. Using the special tool, compress the 1-2 accumulator cover and remove the accumulator piston retaining ring. 2. Note: Note the location of the 1-2 accumulator springs for reference during assembly. Remove the 1-2 accumulator. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 > Page 4532 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. Using the special tool, install the accumulator piston retaining ring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 > Page 4533 Accumulator: Service and Repair 2-3 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive Band Apply Servo: Service and Repair Overdrive Special Tools Removal 1. Remove the main control valve body. 2. 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. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive > Page 4541 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive > Page 4542 Band Apply Servo: Service and Repair Reverse 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. 3. 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. Remove the (A) reverse band servo cover, (B) reverse band servo piston and rod and (C) reverse band servo spring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive > Page 4543 Installation Note: This is not an ordinary installation procedure and does not compensate for band wear. 1. Note: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive > Page 4544 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. 9. Use the Servo Piston Remover/Replacer to install the reverse servo retaining ring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overdrive > Page 4545 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 01-5-8 > Mar > 01 > A/T - 4R70W Ticking Noise In 1ST Gear Clutch: Customer Interest A/T - 4R70W Ticking Noise In 1ST Gear Article No. 01-5-8 March 19, 2001 ^ NOISE - "TICKING" OR "CLICKING" FROM ^ TRANSMISSION - HEARD IN 1ST GEAR ONLY ^ VEHICLES EQUIPPED WITH 4R70W AUTOMATIC ^ TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - "TICKING" OR ^ "CLICKING" NOISE FROM TRANSMISSION - HEARD ^ IN 1ST GEAR ONLY - VEHICLES EQUIPPED WITH ^ 4R7OW AUTOMATIC TRANSMISSION ONLY FORD: 2000-2001 CROWN VICTORIA, MUSTANG, ECONOLINE, F-150 LINCOLN: 2000-2001 TOWN CAR MERCURY: 2000-2001 GRAND MARQUIS ISSUE Some vehicles equipped with the 4R70W automatic transmission may exhibit a "Ticking" or "clicking" type noise in first gear. This may be caused by the intermediate clutch moving inside the transmission. ACTION Install an intermediate clutch anti-rattle clip to correct noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify clicking noise in first (1st) gear only. 2. Lift and support vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. 3 Remove the transmission from the vehicle. Refer to Workshop Manual, Section 307-01. 4. Remove the torque converter and the front pump assembly from the transmission. Remove and discard front pump gasket. Refer to Workshop Manual, Section 307-01. 5. Before installing the anti-rattle clip, push on the clutch plates opposite the 1 o'clock case position. This will provide the maximum opening for the clip to be installed and assure that the rattle clip seats properly on the pressure plate face. NOTE: USE CAUTION WHEN REMOVING PUMP ASSEMBLY FROM TRANSMISSION. THE REVERSE CLUTCH AND FORWARD CLUTCH CYLINDER ASSEMBLIES CAN BE MOVED SO THAT THE DRIVING HUBS DO NOT ENGAGE ALL THE FRICTION PLATE DRIVE SPLINES. THIS WILL CAUSE THE TRANSMISSION END CLEARANCE TO BE REDUCED AND DAMAGE CAN RESULT. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 01-5-8 > Mar > 01 > A/T - 4R70W Ticking Noise In 1ST Gear > Page 4554 6. Install new Intermediate Clutch Anti-Rattle Clip (YL3Z-7A609-AA) in the center of the 1 o'clock case position. Push clip in until fully seated. (Figures 1 and 2). 7. Check that the intermediate clutch and transmission end clearances are correct. Refer to Workshop Manual, Section 307-01. 8. Install transmission pump assembly using a new Pump Gasket (F2VY-7A1 36-A). Refer to Workshop Manual, Section 307-01. 9. Install the transmission and lower vehicle. 10. Fill transmission to the correct level. PARTS BLOCK Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 01-5-8 > Mar > 01 > A/T - 4R70W Ticking Noise In 1ST Gear > Page 4555 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 504000, 597997, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 01-5-8 > Mar > 01 > A/T - 4R70W Ticking Noise In 1ST Gear Clutch: All Technical Service Bulletins A/T - 4R70W Ticking Noise In 1ST Gear Article No. 01-5-8 March 19, 2001 ^ NOISE - "TICKING" OR "CLICKING" FROM ^ TRANSMISSION - HEARD IN 1ST GEAR ONLY ^ VEHICLES EQUIPPED WITH 4R70W AUTOMATIC ^ TRANSMISSION ONLY ^ TRANSMISSION - 4R70W - "TICKING" OR ^ "CLICKING" NOISE FROM TRANSMISSION - HEARD ^ IN 1ST GEAR ONLY - VEHICLES EQUIPPED WITH ^ 4R7OW AUTOMATIC TRANSMISSION ONLY FORD: 2000-2001 CROWN VICTORIA, MUSTANG, ECONOLINE, F-150 LINCOLN: 2000-2001 TOWN CAR MERCURY: 2000-2001 GRAND MARQUIS ISSUE Some vehicles equipped with the 4R70W automatic transmission may exhibit a "Ticking" or "clicking" type noise in first gear. This may be caused by the intermediate clutch moving inside the transmission. ACTION Install an intermediate clutch anti-rattle clip to correct noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify clicking noise in first (1st) gear only. 2. Lift and support vehicle. Refer to the appropriate model year Workshop Manual, Section 100-02. 3 Remove the transmission from the vehicle. Refer to Workshop Manual, Section 307-01. 4. Remove the torque converter and the front pump assembly from the transmission. Remove and discard front pump gasket. Refer to Workshop Manual, Section 307-01. 5. Before installing the anti-rattle clip, push on the clutch plates opposite the 1 o'clock case position. This will provide the maximum opening for the clip to be installed and assure that the rattle clip seats properly on the pressure plate face. NOTE: USE CAUTION WHEN REMOVING PUMP ASSEMBLY FROM TRANSMISSION. THE REVERSE CLUTCH AND FORWARD CLUTCH CYLINDER ASSEMBLIES CAN BE MOVED SO THAT THE DRIVING HUBS DO NOT ENGAGE ALL THE FRICTION PLATE DRIVE SPLINES. THIS WILL CAUSE THE TRANSMISSION END CLEARANCE TO BE REDUCED AND DAMAGE CAN RESULT. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 01-5-8 > Mar > 01 > A/T - 4R70W Ticking Noise In 1ST Gear > Page 4561 6. Install new Intermediate Clutch Anti-Rattle Clip (YL3Z-7A609-AA) in the center of the 1 o'clock case position. Push clip in until fully seated. (Figures 1 and 2). 7. Check that the intermediate clutch and transmission end clearances are correct. Refer to Workshop Manual, Section 307-01. 8. Install transmission pump assembly using a new Pump Gasket (F2VY-7A1 36-A). Refer to Workshop Manual, Section 307-01. 9. Install the transmission and lower vehicle. 10. Fill transmission to the correct level. PARTS BLOCK Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 01-5-8 > Mar > 01 > A/T - 4R70W Ticking Noise In 1ST Gear > Page 4562 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 504000, 597997, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch Clutch: Specifications Direct Clutch Clearance mm (inch) ........................................................................................................................................................... 1.574 - 2.159 (0.062 - 0.085) Snap Ring Thickness mm (inch) .............................................................................................................................................................. ........................ 1.270 - 1.372 (0.050 - 0.054) ...................................................................................... ................................................................................................ 1.625 - 1.727 (0.064 - 0.068) .............. .............................................................................................................................................................. .......... 1.981 - 2.083 (0.078 - 0.082) .................................................................................................... .................................................................................. 2.337 - 2.438 (0.092 - 0.096) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 4565 Clutch: Specifications Forward Clutch Clearance mm (inch) ........................................................................................................................... ........................................ 1.17 - 1.63 (0.046 - 0.068) Snap Ring Thickness mm (inch) .............................................................................................................................................................. .................... 1.524 - 1.625 (0.060 - 0.064) .......................................................................................... ........................................................................................ 1.880 - 1.981 (0.074 - 0.078) ...................... ............................................................................................................................................................ 2.235 - 2.337 (0.088 - 0.092) ............................................................................................................... ....................................................................... 2.591 - 2.692 (0.102 - 0.106) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 4566 Clutch: Specifications Intermediate Clutch Clearance mm (inch) ....................................................................................................................................................... 41.7322 - 42.5958 (1.643 - 1.677) Selective Steel Plates mm (inch) .............................................................................................................................................................. ........................ 1.702 - 1.803 (0.067 - 0.071) ...................................................................................... ................................................................................................ 1.956 - 2.057 (0.077 - 0.081) .............. .............................................................................................................................................................. .......... 2.210 - 2.311 (0.087 - 0.091) .................................................................................................... .................................................................................. 2.464 - 2.565 (0.097 - 0.101) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Direct Clutch > Page 4567 Clutch: Specifications Reverse Clutch Clearance mm (inch) ........................................................................................................................... .................................... 1.27 - 1.94 (0.050 - 0.076) Snap Ring Thickness mm (inch) .............................................................................................................................................................. ........................ 1.524 - 1.625 (0.060 - 0.064) ...................................................................................... ................................................................................................ 1.880 - 1.981 (0.074 - 0.078) .............. .............................................................................................................................................................. .......... 2.235 - 2.337 (0.088 - 0.092) .................................................................................................... .................................................................................. 2.591 - 2.692 (0.102 - 0.106) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 4568 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension Housing Bolts 19 - 22 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ........................................................................ 13.1 L Note: Approximately Dry Fill Capacity Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4579 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4580 Fluid - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, and transmission cooler tubes must be thoroughly flushed to remove any dirt and the Oil-To-Air (OTA) must be replaced. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. The oil-to-air cooler must he 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 failure 2 When used under continuous or server conditions, the transmission and torque converter should be drained and refilled with fluid as specified. + Normal Maintenance Change fluid at 48,000 km (30,000 miles). + Severe Duty/Major Overhaul Change fluid at 48,000 km (30,000 miles). 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. 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. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4581 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 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. Installation 1. Note: A new torque converter drain plug must be used. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4582 Install the torque converter drain plug. 2. Install torque converter housing plug. 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4583 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. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use Motorcraft MERCON (R) V Automatic Transmission Fluid XT-S-QM or equivalent meeting Ford specification MERCON (R) V. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be removed for repair. At this time, the torque converter, and transmission cooler tubes must be thoroughly flushed to remove any dirt and the Oil-To-Air (OTA) must be replaced. The transmission fluid needs to be changed if evidence of fluid contamination is found. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. The oil-to-air cooler must he 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 failure 2 When used under continuous or server conditions, the transmission and torque converter should be drained and refilled with fluid as specified. + Normal Maintenance Change fluid at 48,000 km (30,000 miles). + Sever Duty/Major Overhaul Change fluid at 48,00U km (30,000 miles). 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. 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. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 5. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4587 6. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 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. Installation 1. Note: A new torque converter drain plug must be used. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4588 Install the torque converter drain plug. 2. Install torque converter housing plug. 3. 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 serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. Note: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4589 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. Note: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use Motorcraft MERCON (R) V Automatic Transmission Fluid XT-S-QM or equivalent meeting Ford specification MERCON (R) V. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Fluid Cooler Line Case Fittings 15 - 19 ft.lb Cooler Tube Nut to Case Fitting 13 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Removal and Installation Fluid Line/Hose: Service and Repair Removal and Installation 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Removal and Installation > Page 4595 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 outlet 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 with Motorcraft MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON (R) V. Check for leaks. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Removal and Installation > Page 4596 8. Install the radiator cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Removal and Installation > Page 4597 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes-Backflushing and Cleaning Transmission Fluid Cooler Tubes-Backflushing and Cleaning 1. Using a suitable torque converter/fluid cooler cleaner, clean the fluid cooler tubes. 2. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 3. To aid in attaching the cleaner to the transmission steel cooler tubes, connect two additional rubber hoses to the transmission end of the steel transmission cooler tubes as follows: Disconnect the fluid cooler tubes from the Oil-To-Air (OTA) cooler. - Install a rubber hose in place of the oil-to-air cooler. - Connect the cleaner tank pressure line to the steel transmission cooler return tube (the longest tube). - Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return tube. 6. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tube) until all solvent is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. 8. Install the Oil-To-Air (OTA) cooler tubes. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4612 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4613 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4614 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4620 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4621 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 4622 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Planetary Gears: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stoplamp: 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Planetary Gears: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 4628 (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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Planetary Gears: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 4634 (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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. 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. 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 EPC solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4638 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the EPC solenoid. - Connect the TCC. - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T Seals and Gaskets: Service and Repair Extension Housing Seal, A/T Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Drain the transmission fluid. 4. 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. Remove the driveshaft. Remove the four bolts. 5. Separate the driveshaft from the transmission. 6. Use a high-lift transmission jack to support the transmission. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4643 7. Remove the two transmission mount nuts. 8. Remove the transmission crossmember. - Remove the bolts. - Remove the transmission crossmember. 9. Lower the transmission to access the extension housing bolts. 10. Use the (A) Oil Seal Remover and the (B) Impact Slide Hammer, remove the (C) extension housing seal. 11. Remove the Vehicle Speed Sensor (VSS). 1 Disconnect the connector. 2 Remove the bolt. 3 Remove the Vehicle Speed Sensor (VSS). 12. Remove the extension housing and gasket. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4644 1 Remove the bolts and the nuts. 2 Remove the extension housing and gasket. Installation 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 Vehicle Speed Sensor (VSS). 1 Install the Vehicle Speed Sensor (VSS). 2 Install the bolt. 3 Connect the connector. 3. Install the new extension housing seal. 1 Align Extension Housing Seal Replacer with the seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4645 2 Install the extension housing seal. 4. Raise and position the transmission. 5. Install the transmission crossmember. 1 Position the transmission crossmember. 2 Install the bolts. 6. Remove the high-lift transmission jack. 7. Install the two transmission mount nuts. 8. Note: The output shaft and the driveshaft are a balanced assembly. Install the driveshaft. Align the yellow dots and position the driveshaft on the transmission. - Install the driveshaft. 9. Install the four retaining bolts. 10. Lower the vehicle. 11. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4646 12. Fill the transmission with fluid and inspect for proper operation. - Use Motorcraft MERCON (R) V Automatic Transmission Fluid XT-S-QM or equivalent meeting Ford specification MERCON (R) V. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4647 Seals and Gaskets: Service and Repair Shift Shaft Seal Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Drain the transmission fluid and remove the fluid pan and filter. 4. Disconnect the digital TR sensor electrical connector. 5. Disconnect the transmission shift linkage. 6. Remove the digital TR sensor. - Remove the bolts. - Remove the digital TR sensor. 7. Remove the manual control valve detent lever spring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4648 1 Remove the bolt. 2 Remove the manual control valve detent lever spring. 8. Note: Use a shop cloth to protect the transmission case surface. Remove the manual lever shaft retaining pin. 9. Remove the nut and slide the manual control lever shaft out of the case. 10. Remove the parking lever actuating rod. 1 Remove the manual valve detent lever. 2 Remove the parking lever actuating rod. 11. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4649 Remove the manual control lever shaft seal. Installation 1. Using the (A) Shift Seal Replacer, install the (B) manual control lever shaft 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 control lever shaft retaining pin. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4650 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. 6. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 4651 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. Fill the transmission with fluid and inspect for proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4661 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4667 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4671 Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4672 Transmission Mode Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4676 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4677 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4678 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4679 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4680 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4684 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4685 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4690 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. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4699 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4705 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair 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 1. Note: The selector lever pin must be replaced whenever removed. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Bracket Bolts 17 - 23 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Cable and Bracket Adjustment-Shift Cable Shift Cable: Adjustments Cable and Bracket Adjustment-Shift Cable 1. Place the selector lever in the O/D position. - Place 1.36 Kg (3 lb.) 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 lb.) 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 adjustment in NEUTRAL. Readjust if necessary. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Cable and Bracket Adjustment-Shift Cable > Page 4715 Shift Cable: Adjustments Cable and Bracket Adjustment-Shift Indicator Cable 1. Remove the upper instrument panel steering column cover. 2. Place the transmission range selector lever in the (D) position. - Rotate the transmission range selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (O/D position). 3. Hang a 1.36 Kg (3 lb.) weight on the range selector lever. 4. Center the pointer in the middle of the O/D position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 1.36 Kg (3 lb.) weight. 6. Carefully move the shift range selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4716 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4717 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 VIN W (2000)) 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 VIN W (2000)) 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 4722 ^ 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 VIN W (2000)) 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 4723 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 VIN W (2000)) 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 VIN W (2000)) 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 4728 ^ 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 VIN W (2000)) 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 4729 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Stall Speed 4.6L Min 2094 Max 2440 4.6L Police Applications Min. 2319 Max. 2750 End Play New or Rebuilt 0.014 - 0.041 in Used 0.014 - 0.074 in Torque Converter Drain Plug 21 - 22 ft.lb Torque Converter Nuts 20 - 33 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4733 Torque Converter: Service and Repair For service information relating to this component, please refer to the procedures shown at Automatic Transmission/Transaxle; Service and Repair; Disassembly and Assembly of Subassemblies. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Transmission Fluid Cooler Fittings 19 - 20 ft.lb Transmission Fluid Cooler Mounting Bolts 12 - 14 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Removal and Installation 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 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Removal and Installation > Page 4742 6. Remove the upper radiator mounts. 7. Remove the screws 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 bolts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Removal and Installation > Page 4743 3. Connect the power steering lines to the fluid cooler. 4. Connect the fluid cooler 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Removal and Installation > Page 4744 Transmission Cooler: Service and Repair Transmission Fluid Cooler - 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 recurring transmission concerns and must be removed from the system before the system is put back into service. The OTA fluid cooler is not serviceable with existing equipment due to the thermostatic bypass valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4748 Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4749 Transmission Mode Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Transmission Mount Nuts 25 - 34 ft.lb Transmission Mount Bolts 50 - 68 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Insulator and Retainer Transmission Mount: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Insulator and Retainer > Page 4755 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4759 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4760 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4761 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4762 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4763 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4767 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4768 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4772 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. 4. 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. 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. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4773 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 1. 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. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. 2. Note: The main control valve body bolts will be tightened in later steps. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4774 Loosely install the bolts. 3. Note: The main control valve body bolts will be tightened in later steps. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4775 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4776 - 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. 8. 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. Replace fluid filter and seal as required. 9. Position the (B) pan magnet into the (A) transmission fluid pan. 10. Note: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4777 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. Additional Service Information For additional service information relating to this component, please refer to the procedures shown at Automatic Transmission/Transaxle; Service and Repair; Disassembly and Assembly of Subassemblies. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications Maximum Differential Case Runout ............................................................................................................................................. 0.076 mm (0.003 inch) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4782 Differential Case: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4783 3. Rotate the differential assembly to check for roughness indicating bearing/gear damage. 4. Using the special tool, measure and note the differential ring gear back face runout. 5. CAUTION: Mark the position of the differential bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions. Remove the differential bearing caps. 1 Remove the bolts. 2 Remove the differential bearing caps. 6. WARNING: Do not allow the differential assembly to fall. CAUTION: Place a wood block between the pry bar and the differential housing to protect the machined surface from damage. Using a pry bar and a wood block, remove the differential assembly from the differential housing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4784 7. Remove the bolts. 8. CAUTION: Do not damage the differential ring gear bolt hole threads. Insert a punch in the bolt holes, and drive off the differential ring gear. 9. If the differential ring gear back face runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary, Drive Pinion, Differential Case and Ring Gear-Conventional or Differential Case and Ring Gear-Traction-Lok, or to Installation. If the differential ring gear back face runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout. 10. Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the differential bearing caps and the bolts. 11. Position the special tool. 1 Rotate the differential case to verify that the differential bearings have seated correctly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4785 2 Position the special tool. 12. Measure and note the differential case runout. - If the runout does not exceed the specification, install a new differential ring gear and pinion. - If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows. 13. Using the special tools, remove the differential bearings. 14. Using the special tool, install the new differential bearings. 15. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten differential bearing caps to specification. 16. Position the special tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4786 1 Rotate the differential case to verify that the differential bearings have seated correctly. 2 Position the special tool. 17. Measure the differential case runout. - If the runout does not exceed the specification, use the new differential bearings for assembly. - If the runout exceeds the specification, install a new differential case. Installation All vehicles 1. Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case. 2. Install the bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4787 3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing. 4. Install a differential bearing shim on the left side. 5. CAUTION: Always install the differential bearing caps in their identical locations and positions. Note: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly. Install the left differential bearing cap and loosely install the bolts. 6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4788 7. Install the right side differential bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential case to make sure it turns freely. Measuring backlash Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4789 9. Using the special tools, measure and note the differential ring gear backlash. - If backlash is within the specification. The specification shown is the full allowable range. - If a zero backlash condition occurs, refer to Zero backlash. - If backlash is not within the specification, refer to Backlash not within specification. Zero backlash 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. Measure the backlash. Backlash not within specification 11. To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly. - If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4790 12. Rotate the differential assembly several times to verify that the differential bearings seated correctly. 13. Using the special tools, recheck the backlash. - If backlash is within the specification, refer to Backlash within specification. If backlash is not within the specification, repeat Backlash not within specification. - The specification shown is the full allowable range. Backlash within specification 14. Remove the bolts and the differential bearing caps. 15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown. 16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Page 4791 17. Install the differential bearing caps and bolts. 18. Using the special tools, recheck the backlash. - The specification shown is the full allowable range. 19. Install the axle shafts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Differential Housing Cover Bolt ........................................................................................................... .................................................... 45 Nm (33 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4795 Differential Cover: 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 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. Note: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1 Remove the bolts and drain the lubricant from the differential housing. 2 Remove the differential housing cover. Installation 1. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination. Clean the gasket mating surfaces. 2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant. Apply a continuous bead of sealant to the differential housing cover. Use Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specification ESB-M4G92-A. 3. Note: If possible, allow one hour before filling the axle with lubricant to allow the silicone sealant to cure. Install the differential housing cover. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4796 1 Position the differential housing cover. 2 Install the bolts. 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml. (4 oz.) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. Note: Service refill capacities are determined by filling the rear axle with the specified lubricant to the level shown in the illustration. Fill the rear axle with 1.8 liters (3.75 pints) of lubricant and install the fill plug. Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 5. Note: If equipped with air suspension, reactivate the system. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Casting Porosity (Holes In Casting) Repair Differential Axle Housing: Service and Repair Casting Porosity (Holes In Casting) Repair CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier. Note: Casting porosity is a condition where occasionally gas bubbles will form during the casting process, leaving small pockets in the metal that will cause the axle housing to leak. 1. To fill small pockets, peen in a small amount of body lead. 2. Seal the pocket. - Use Devcon Aluminum Liquid F2 meeting Ford specification M-3D35A (E). 3. To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it. - Use Devcon Aluminum Liquid F2 meeting Ford specification M-3D35A (E). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Casting Porosity (Holes In Casting) Repair > Page 4801 Differential Axle Housing: Service and Repair Weld Leaks Repair 1. CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier. CAUTION: Rear axle housing straightness is too critical for field repair. Install a new axle housing if a weld is broken. Note: Most minor weld leaks are repairable. This includes the puddle and fill welds that join the axle shaft tube to the axle housing on integral axles. Seal the weld. Use Devcon Aluminum Liquid F2 meeting Ford specification M-3D35A (E). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Fill Plug ................................................................................................................................................ .................................................... 30 Nm (22 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ....................................................................... 3.75 pt Additive Friction Modifier ................................. ............................................................................................................................................................. 4 oz Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4809 Fluid - Differential: Fluid Type Specifications Differential Fluid Type 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications Differential Pinion Bearing Preload (Used Pinion Bearings) 8 - 14 in.lb Differential Pinion Bearing Preload (New Pinion Bearings) 16 - 29 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Special Tools 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 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. Remove the rear wheel and tire assemblies. 2. CAUTION: Remove the rear brake discs to prevent brake drag during drive pinion bearing preload adjustment. Remove the rear brake discs. 3. CAUTION: Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Remove the driveshaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4816 4. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions. 5. CAUTION: Discard the nut after removing it. Install a new nut during installation. Use the special tool to hold the pinion flange while removing the nut. 6. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. 7. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Note: Disregard the index marks if installing a new pinion flange. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4817 Position the pinion flange. 3. Using the special tool, install the pinion flange. 4. Position the new nut. 5. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. - Refer to torque specifications for used pinion bearings. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 4818 6. CAUTION: Align the index marks. Install the driveshaft. 7. Install the rear brake discs and calipers. 8. Note: If equipped with air suspension, reactivate the system. Install the rear wheel and tire assemblies. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4822 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4823 Special Tools Removal 1. Remove the differential case. 2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange. Remove the pinion flange. 3. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. 4. Using gripping pliers and a hammer, remove the rear axle drive pinion seal. 5. Remove the rear axle drive pinion shaft oil slinger. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4824 6. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the front differential pinion bearing and remove it through the rear of the differential housing. 7. Remove the differential drive pinion collapsible spacer and discard it. 8. Using the special tool and a suitable press, remove the differential pinion bearing. 9. Note: Do not remove the differential drive pinion bearing cups from the differential housing unless the cups are damaged. Using the special tools, remove the outer differential drive pinion bearing cup. 10. Using the special tools, remove the inner differential drive pinion bearing cup. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4825 1. Note: This step and the following step show the preferred method for installing the differential drive pinion bearing cups. An alternate method is shown following these two steps. Position the special tools and the inner and outer differential drive pinion 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 bearing cup. 2 Place the special tool on the outer bearing cup. 3 Install the special tool into the replacer tools. 2. Tighten the special tool to seat the differential drive pinion bearing cups into their bores. 3. Note: This step and the following step are alternate methods for installing the differential drive pinion bearing cups. Carry out these two steps if differential drive pinion bearing cup installation was not done in the previous steps. Using the special tools, drive the outer differential drive pinion bearing cup into the differential housing. 4. Using the special tools, drive the inner differential drive pinion bearing cup into the differential housing. 5. CAUTION: Always install new differential pinion bearings when installing new differential drive pinion bearing cups. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4826 Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. 6. Note: Apply only a light oil film on the differential pinion bearings before assembling the tool. Assemble and position the following in the differential housing. 7. Note: This step duplicates final differential pinion bearing preload. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4827 Tighten the special tool to the specification shown. 8. CAUTION: Offset the special tool to obtain an accurate reading. Rotate the special tool several half-turns to make sure the differential pinion bearings seat correctly and position the special tool as shown. 9. Install the special tool. 1 Position the special tool. 2 Install the differential bearing caps. 3 Install the bolts. 10. CAUTION: Use only flat, clean drive pinion bearing adjustment shims. CAUTION: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. After determining the correct shim thickness, remove the special tools. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4828 11. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion. Using a suitable press and the special tools, press the differential pinion bearing until it seats firmly on the pinion. 12. Place a new differential drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. CAUTION: Installation without the correct tool can result in early seal failure. Install a new rear axle drive pinion seal. 1 Install the front differential pinion bearing. 2 Install the rear axle drive pinion shaft oil slinger. 3 Position the rear axle drive pinion seal on the special tool. 14. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Note: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4829 15. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the carrier bore. 16. Lubricate the pinion flange splines. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 17. Note: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 18. Using the special tool, install the pinion flange. 19. Position the new nut. 20. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Page 4830 CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. - For new differential pinion bearings, tighten the nut to specification. Refer to torque specifications for new differential pinion bearings. - For used differential pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. Refer to torque specifications for used differential pinion bearings. - For used differential pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 21. Install the differential case in the differential housing. 22. Install the driveshaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications Clearance, Tolerance and Adjustments Maximum Differential Ring Gear Back face Runout .................................................................................................................... 0.102 mm (0.004 inch) Backlash Between Differential 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 in preferred) Maximum Differential Ring Gear Backlash Variation Between Teeth .............................................................................................................................................................. .................................. 0.102 mm (0.004 inch) Torque Specifications Differential Ring Gear Bolt ................................................................................................................... ............................................ 105 Nm (77 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 rear axle drive pinion seal metal flange up and strike it with a hammer. 3. Using gripping pliers and a hammer, remove the seal. Installation 1. Coat the new rear axle drive pinion seal lips with lubricant. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Installation without the correct tool can result in early seal failure. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Maximum Axle Shaft End Play 0.030 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4842 Axle Shaft: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the rear wheel bearings. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. 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. Raise and support the vehicle. 3. Remove the rear 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 rear brake caliper and the brake disc. 7. 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4843 Remove the differential pinion shaft. 1 Remove the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 8. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1 Push the axle shaft inboard. 2 Remove the U-washer. 9. Reinstall the differential pinion shaft. 1 Push the axle shaft outboard. 2 Install the differential pinion shaft. 3 Install the differential pinion shaft lock bolt finger-tight. 10. CAUTION: Do not damage the wheel bearing oil seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4844 Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. 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. Remove the differential pinion shaft. 1 Remove the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 3. CAUTION: Do not damage the wheel bearing oil seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4845 Install the axle shaft. 4. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Install the U-washer. 1 Position the U-washer on the button end of the axle shaft. 2 Pull the axle shaft outward to seat the U-washer in the side gear. 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 disc and the brake caliper. 7. Install the rear brake anti-lock sensor. 8. Install the differential housing cover and fill the differential housing with the specified lubricant. 9. 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. Clean the wheel hub and mounting surfaces. 10. Install the wheel and tire assembly. 11. Install the center cap. 12. Note: If equipped with air suspension, reactivate the system by turning the air suspension switch on. Lower the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 4849 2. Using the special tool, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tool, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 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. 2. Spin the tire by hand to check the wheel bearings for roughness. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 4855 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 4856 Wheel Bearing: Testing and Inspection Wheel Bearing 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 4857 Wheel Bearing: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 4858 2. Using the special tool, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tool, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 221 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Suspension/Driveline - Vibration Diagnosis Drive/Propeller Shaft: 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Suspension/Driveline - Vibration Diagnosis > Page 4868 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Suspension/Driveline - Vibration Diagnosis > Page 4869 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Suspension/Driveline - Vibration Diagnosis > Page 4870 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Suspension/Driveline - Vibration Diagnosis > Page 4871 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Suspension/Driveline - Vibration Diagnosis > Page 4872 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4873 Drive/Propeller Shaft: Specifications Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints Drive/Propeller Shaft: Description and Operation Universal Joints 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints > Page 4876 Drive/Propeller Shaft: Description and Operation Driveshaft 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Page 4877 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 1. Note: Inspect the extension housing seal for damage, install new as necessary. Note: Lubricate the slip-yoke spline with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Note: 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. Note: 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. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair Universal Joint: Service and Repair Special Tools Disassembly 1. CAUTION: Do not clamp the driveshaft in the jaws of a vice or a similar holding fixture. Place the driveshaft on a suitable workbench. 2. 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. Index the driveshaft and driveshaft components. 3. Clamp the U-Joint Tool in a vise. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4881 4. Remove the snap rings. 5. Note: If the bearing cup cannot be pressed all the way out, remove it with vise grips. 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. 8. Note: If the bearing cup cannot be pressed all the way out, remove it with vise grips. Remove the driveshaft centering socket yoke. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4882 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 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. 2. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4883 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. 5. 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. Remove the driveshaft from the U-Joint Tool and install the snap ring. 6. Repeat Steps 4 and 5 for the opposite side. 7. Note: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer. Check the universal joint for freedom of movement. 8. Install a new bearing cup. 1 Start a new bearing cup into the driveshaft yoke. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4884 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. 9. 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. 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. 12. 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. Remove the driveshaft from the U-Joint Tool and install the snap ring. 13. Repeat Steps 11 and 12 for the opposite side. 14. Note: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer to seat the bearing cups. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 4885 Check the universal joint for freedom of movement. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4889 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4900 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4906 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 VIN W (2000)) 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 VIN W (2000)) 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 4910 Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4911 Transmission Mode Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4915 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4916 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4917 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4918 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4919 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4923 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4924 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Removal 1. Remove the manual control lever. 2. 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. 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 EPC solenoid. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 4931 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the EPC solenoid. - Connect the TCC. - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4935 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. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > Customer Interest for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4949 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Lock Switch <--> [Shift Interlock Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Lock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4955 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 VIN W (2000)) 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 VIN W (2000)) 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 4959 Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4960 Transmission Mode Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) Sensor Bolts 62 - 88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4964 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4965 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4966 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4967 Digital Transmission Range Sensor: Service and Repair Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the manual lever shift control cable. 4. Loosen the digital TR bolts. 5. Note: Manual shift lever shaft must be in the neutral position. Using the TRS Alignment Tool, align the digital TR sensor slots. The tool is designed to fit snugly. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4968 6. Tighten the bolts. 7. With the manual lever in overdrive, connect the shift lever control cable. 8. Install the digital TR sensor electrical connector. 9. Lower the vehicle. 10. Connect the battery ground cable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4972 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 4973 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Conventional ABS Light: Description and Operation Conventional Anti-Lock Brakes The anti-lock brake warning indicator illuminates when the anticlock brake control module detects a fault in the system. For further information regarding this component and the system that it is a part of, please refer to; Brakes and Traction Control/ Testing and Inspection. Brake System 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. For additional information, refer to Brake Warning Indicator. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Conventional > Page 4980 ABS Light: Description and Operation Electronic Anti-Lock Brakes The anti-lock brake warning indicator is located in the indicator lamp module and illuminates when the anti-lock brake control module detects a fault in the system. Brake System The brake system warning indicator is located in the indicator lamp module and 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. For additional information, refer to Brake Warning Indicator. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-Lock Brake Control Module 1.8 - 2.8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4984 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4985 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4986 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4987 Electronic 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 VIN W (2000)) 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 fm00cvigm_all fm00cvigm_all Hydraulic Control Unit (HCU) Mounting Bolts 11 - 12 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4991 Hydraulic Control Assembly - Antilock Brakes: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4992 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4993 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4994 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Brake Anti-Lock Sensor 36 - 53 in.lb Rear Brake Anti-Lock Sensor 14 - 19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5000 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5001 Wheel Speed Sensor: Service and Repair Sensor, 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5002 2 Remove the sensor. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Front Disc Brake Caliper Bleeder Screw 9 - 13 ft.lb Front Master Cylinder Brake Tube 17 - 20 ft.lb Rear Bleeder Screw 12 - 18 ft.lb Rear Master Cylinder Brake Tube 11 - 14 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 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. Refer to Specifications. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5008 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Hush 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 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 scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the scan tool 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5009 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5010 Brake Bleeding: Service and Repair Brake System 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5011 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) 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. 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. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5012 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 scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the scan tool instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5013 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5014 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. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE J1704-DOT 4. 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. 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 5015 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal Bracket Nuts 16 - 21 ft.lb Brake Pedal Bracket Bolt 16 - 21 ft.lb Brake Pedal Pivot Shaft Nut 10 - 20 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5019 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5020 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5021 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Conventional Brake Warning Indicator: Description and Operation Conventional Anti-Lock Brakes The anti-lock brake warning indicator illuminates when the anticlock brake control module detects a fault in the system. For further information regarding this component and the system that it is a part of, please refer to; Brakes and Traction Control/ Testing and Inspection. Brake System 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Conventional > Page 5026 Brake Warning Indicator: Description and Operation Electronic Anti-Lock Brakes The anti-lock brake warning indicator is located in the indicator lamp module and illuminates when the anti-lock brake control module detects a fault in the system. Brake System The brake system warning indicator is located in the indicator lamp module and 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Disc Brake Caliper Bolt 21 - 26 ft.lb Front Disc Brake Caliper Anchor Plate Bolt 125 - 169 ft.lb Disc Brake Caliper Bleeder Screw 13 - 17 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 5032 Brake Caliper: Specifications Brake Caliper Bolts 20 ft.lb Caliper Flow Bolt 37 ft.lb Rear Wheel Disc Brake Adapter Nuts 50 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation 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, 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, 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5035 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 Motor Vehicle 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-J1704-DOT Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5036 4. Install brake master cylinder filler cap. 6. Inspect the brake system operation. Caliper Disassembly and Assembly 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. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5037 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. ^ Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper pistons. ^ Clean the caliper bores with Brake Parts Cleaner F6AZ-2C410-A.B 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 with clean brake fluid before assembly. Refer to Specifications. 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 Motor Vehicle Brake Fluid C6A7-19542-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-J1704-DOT 4. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5038 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. Brake Caliper 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5039 Brake Caliper: Service and Repair Rear Caliper Removal and Installation 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-MIC171-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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5040 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5041 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. Caliper Disassembly and Assembly 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5042 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 period of time. 1. Lubricate the following with Ford High Performance DOT 3 Motor Vehicle 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-J1704-DOT 4. ^ cylinder bore ^ piston seal ^ rear brake disc piston ^ dust boot 2. Install the piston seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5043 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear brake disc piston. 5. Install the rear disc brake caliper. Rear Disc Brake Adapter 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5044 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 5058 Brake Pad: Specifications Brake Pads (Front and Rear) Brake pad minimum thickness .......................................................................................................................................................... 3.0 mm (0.118 inch) Brake pad maximum thickness variation (pad-to-pad) ..................................................................................................................... 2.0 mm (0.079 inch) Brake pad maximum taper wear (in any direction) ........................................................................................................................... 3.0 mm (0.118 inch) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5061 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 disc brake caliper anchor plate stainless steel slippers and discard. 10. Inspect the 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. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5062 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. Install the pads. 1 Install the new disc brake caliper anchor plate stainless steel slippers. If required, make sure the slippers are clean and in good condition. 2 Install the pads. 2. Note: Use a wood block or used pad to protect pistons and boots. Compress the caliper pistons. 3. Install the disc brake pad anti-rattle clip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5063 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 Motor Vehicle Brake Fluid C6A-Z-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-J1704-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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5064 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5065 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Brake Disc Front Brake disc minimum thickness ............................................................................................................................................... 25.75 mm (1.0138 inch) Rear Brake disc minimum thickness ................................................................................................................................................. 13.0 mm (0.5118 inch) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Brake Disc 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. 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. Installation 1. Clean any rust or debris from brake disc and wheel hub. ^ Use Brake Parts Cleaner F6AZ-2C410-AB 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. Align the hub and brake disc marks and position the brake disc to the wheel hub. 4. Install the front disc brake caliper anchor plate. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 5071 5. Check Total Indicated Runout (TIR). Brake Disc Shield Removal 1. Remove the brake disc. 2. Remove the brake disc shield. 1 Using a suitable punch, remove the rivet mandrel, and drill out three brake disc shield rivets. 2 Remove the brake disc shield. Installation 1. Install the brake disc shield. 1 Position the shield. 2 Secure with three rivets. 2. Install the brake disc. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 5072 Brake Rotor/Disc: Service and Repair Rear Brake Disc 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. 2. Note: If the brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and retract the parking brake shoe and lining using an adjusting tool. Insert the tool at the end of the access plug slot farthest from the brake caliper. Engage the adjuster and rotate by raising the end of the tool toward the backing plate. 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. ^ 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 5073 3. Install the rear brake disc. 4. Install the rear disc brake caliper. Brake Disc Shield 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. 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 Clear 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Front Disc Brake Caliper Bleeder Screw 9 - 13 ft.lb Front Master Cylinder Brake Tube 17 - 20 ft.lb Rear Bleeder Screw 12 - 18 ft.lb Rear Master Cylinder Brake Tube 11 - 14 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 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. Refer to Specifications. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5094 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Hush 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 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 scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the scan tool 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5095 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5096 Brake Bleeding: Service and Repair Brake System 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5097 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) 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. 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. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5098 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 scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the scan tool instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5099 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 5100 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. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE J1704-DOT 4. 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. 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 5101 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Disc Brake Caliper Bolt 21 - 26 ft.lb Front Disc Brake Caliper Anchor Plate Bolt 125 - 169 ft.lb Disc Brake Caliper Bleeder Screw 13 - 17 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 5106 Brake Caliper: Specifications Brake Caliper Bolts 20 ft.lb Caliper Flow Bolt 37 ft.lb Rear Wheel Disc Brake Adapter Nuts 50 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation 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, 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, 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5109 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 Motor Vehicle 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-J1704-DOT Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5110 4. Install brake master cylinder filler cap. 6. Inspect the brake system operation. Caliper Disassembly and Assembly 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. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5111 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. ^ Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper pistons. ^ Clean the caliper bores with Brake Parts Cleaner F6AZ-2C410-A.B 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 with clean brake fluid before assembly. Refer to Specifications. 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 Motor Vehicle Brake Fluid C6A7-19542-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-J1704-DOT 4. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5112 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. Brake Caliper 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5113 Brake Caliper: Service and Repair Rear Caliper Removal and Installation 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-MIC171-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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5114 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5115 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. Caliper Disassembly and Assembly 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5116 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 period of time. 1. Lubricate the following with Ford High Performance DOT 3 Motor Vehicle 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-J1704-DOT 4. ^ cylinder bore ^ piston seal ^ rear brake disc piston ^ dust boot 2. Install the piston seal. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5117 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear brake disc piston. 5. Install the rear disc brake caliper. Rear Disc Brake Adapter 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5118 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid Type ................................................................................................................................. ......................................... High Performance DOT 3 Ford Specifications .............................................................................................................................. ....................................................... ESA-M6C25-A Brake Fluid Type ................................................................................................................................. ......................................... High Performance DOT 4 Ford Specifications .............................................................................................................................. ............................................... SAE-J-1704-DOT 4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5122 Brake Fluid: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6A7-19542-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-J1704-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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Line Connections to Brake Pressure Control Valve Block M10 X 1 12 ft.lb M12 x 1 12 ft.lb M14 x 1.5 12 ft.lb Hydraulic Tube Connections 10 - 14 ft.lb Front Brake Hose Bolt 35 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5126 Brake Hose/Line: Description and Operation 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 VIN W (2000)) 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 10 - 17 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 5130 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications fm00cvigm_all fm00cvigm_all Hydraulic Control Unit (HCU) Mounting Bolts 11 - 12 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5134 Hydraulic Control Assembly - Antilock Brakes: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5135 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5136 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5137 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder Brake Master Cylinder: Specifications Brake Master Cylinder Nuts 16 - 21 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder > Page 5142 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder Brake Master Cylinder: Description and Operation Brake Master Cylinder 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder > Page 5145 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Abnormal Conditions Brake Master Cylinder: Testing and Inspection 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 at Brakes and Traction Control/Testing and Inspection for abnormal condition diagnosis. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Abnormal Conditions > Page 5148 Brake Master Cylinder: Testing and Inspection 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Abnormal Conditions > Page 5149 Brake Master Cylinder: Testing and Inspection 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Abnormal Conditions > Page 5150 Brake Master Cylinder: Testing and Inspection 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 5151 Brake Master Cylinder: Adjustments Master Cylinder Push Rod Adjustment 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5154 1. Follow the removal procedure in reverse order. ^ Bleed the brake system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5155 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-1704-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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Torque Specifications Parking Brake Rear Cable And Conduit Retaining Bolts ............................................................................................................ 12-15 Nm (9-11 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 5160 Parking Brake Cable: Adjustments 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 and support the vehicle. 3. Pull the parking brake cable adjuster clip downward. The tensioner spring will take up the cable slack and preload the cables. 4. Push up on the bottom of the clip to lock adjustment. If the clip does not slide up, move the assembly slightly to align the closest groove on the parking brake cable adjuster rod with the clip. 5. Note: If new cables are installed, allow 20 minutes prior to releasing the parking brake control. Apply the parking brake control with 556 N (125 lb) foot-pedal effort and release using the parking brake release handle. 6. Pull the parking brake cable adjuster clip downward. The tensioner spring will take up the cable slack and preload the cables. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 5161 7. Push up on the bottom of the clip to lock adjustment. If the clip does not slide up, move the assembly slightly to align the closest groove on the parking brake cable adjuster rod with the clip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front Parking Brake Cable: Service and Repair Cable and Conduit - 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5164 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. Pull back the front fender apron to expose the front parking brake cable and conduit. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5165 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5166 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5167 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5168 Parking Brake Cable: Service and Repair Cable and Conduit - 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5169 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5170 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5171 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5172 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 5173 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Torque Specifications Parking Brake Control Retaining Bolts ................................................................................................................................. 25 - 35 Nm (19 25 ft. lbs.) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5177 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 upon the parking brake adjuster clip to lock the adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5178 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5179 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5180 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5181 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5182 1. Position the parking brake control. 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5183 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5184 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 5185 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking Brake Release Handle Screw 9 - 17 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 springs. ^ A sharp-pointed tool such as a scratch awl is useful in removing and installing the springs. 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 High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A. ^ Lubricate the adjusting screw threads with High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5192 ^ Adjust the parking brake cable tension. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake Booster Retaining Nut 16 - 21 ft.lb Brake Master Cylinder Nuts 16 - 21 ft.lb Power Brake Booster Push Rod Length 0.980 - 0.995 in Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5197 Vacuum Brake Booster: Description and Operation The power brake booster: ^ is a single 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 diaphragms. ^ 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5198 Vacuum Brake Booster: Testing and Inspection 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Continue with the following steps. 4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2 and 3. 5. If no downward movement of the brake pedal is felt, install a new power brake booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new power brake booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5199 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5200 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5201 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5202 1. CAUTION: The brake switch must be positioned with the closed hole away from the brake pedal arm and the open hole facing upward. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 5206 Vacuum Brake Booster Check Valve: Testing and Inspection The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster check valve. Do not remove the power brake booster check valve from the power brake booster. ^ There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-Lock Brake Control Module 1.8 - 2.8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5211 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5212 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5213 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5214 Electronic 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front Brake Anti-Lock Sensor 36 - 53 in.lb Rear Brake Anti-Lock Sensor 14 - 19 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5221 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5222 Wheel Speed Sensor: Service and Repair Sensor, 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 VIN W (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 5223 2 Remove the sensor. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 5231 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 5232 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 VIN W (2000)) 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 5233 ^ 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 VIN W (2000)) 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 5234 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 VIN W (2000)) 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 5235 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Installation Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5238 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Installation 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. 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5239 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. Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5240 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. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5241 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5245 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5253 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5254 Starter Relay: Description and Operation STARTING SYSTEM The starting system consists of the: - starter motor. - ignition switch. - digital transmission range (TR) sensor. - mini ISO relay. Starter Motor The starter motor: - is a permanent-magnet, gear reduction, 12V DC motor. - has an integral starter solenoid. Starter Relay 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. Normal Operation When the digital TR sensor recognizes that the vehicle is in either PARK or NEUTRAL and the ignition switch is placed in the START position, it sends a signal to the mini ISO relay that, in turn, sends a voltage signal to the starter solenoid, which will engage the starter motor to crank the engine at a speed fast enough to permit the engine to start. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5255 Starter Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5256 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Cable Terminals 9 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 5261 Battery Cable: Description and Operation Vehicles are equipped with a 12 volt maintenance-free battery. The battery and cable system consists of the following components: ^ battery ^ battery cable assembly ^ battery tray 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical Specifications Rating (gen. crank/rev.) 130 A AMP/MAX Generator Ratio 2.72:1 Amperage Output (At Least) 87 A at 2,000 rpm Voltage Output 13.0 - 15.0 V at 2,000 rpm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 5267 Generator: Mechanical Specifications Generator Mounting Bolts 20-30 Nm Generator battery lead nut 89 in.lb Generator support bracket (NGV) 89 in.lb Generator to intake bracket bolts 71 - 106 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions Generator: 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 Generator: 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 5284 Generator: Service Precautions CAUTION: ^ To prevent damage to the generator, do not make jumper wire connections except as directed. ^ Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 5285 Generator: 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Generator Testing Generator: Testing and Inspection Generator Testing CAUTION: ^ To prevent damage to the generator, do not make jumper wire connections except as directed. ^ Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes. NOTE: ^ Battery posts and cable clamps must be clean and tight for accurate meter indications. ^ Refer to the battery tester manual for complete directions for testing the charging system. 1. Turn off all lamps and electrical components. 2. Place the vehicle in transmission range NEUTRAL and apply the parking brake. 3. Carry out the Load Test and No-Load Test according to the following component tests: Load Test 1. Switch the tester to the ammeter function. 2. Connect the positive and negative leads of the tester to the corresponding battery terminals. 3. Connect the current probe to the generator B+ output terminal, circuit 38 (BK/OG). 4. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the generator. Generator output should be at least 87 amps. 130 Amp Generator 5. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam. 6. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. ^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. ^ If the voltage increases as specified, the charging system is operating normally. No Load Test 1. Switch the tester to the voltmeter function. 2. Connect the voltmeter positive lead to the generator B+ terminal and the negative lead to ground. 3. Turn all electrical accessories off. 4. With the engine running at 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts. If not, refer to the Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 5288 Generator: 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 5289 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 5299 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 5300 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 VIN W (2000)) 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 5301 ^ 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 VIN W (2000)) 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 5302 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 VIN W (2000)) 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 5303 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Installation Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5306 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Installation 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. 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5307 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. Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5308 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. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5309 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5313 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 5322 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 5328 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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; refer to 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; refer to 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; refer to Starter Motor. Replace the flywheel ring gear; refer to Engine. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5336 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5337 Starter Relay: Description and Operation STARTING SYSTEM The starting system consists of the: - starter motor. - ignition switch. - digital transmission range (TR) sensor. - mini ISO relay. Starter Motor The starter motor: - is a permanent-magnet, gear reduction, 12V DC motor. - has an integral starter solenoid. Starter Relay 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. Normal Operation When the digital TR sensor recognizes that the vehicle is in either PARK or NEUTRAL and the ignition switch is placed in the START position, it sends a signal to the mini ISO relay that, in turn, sends a voltage signal to the starter solenoid, which will engage the starter motor to crank the engine at a speed fast enough to permit the engine to start. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5338 Starter Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5339 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Terminal Nuts 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5348 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5349 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5350 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 5375 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 VIN W (2000)) 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 5376 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 VIN W (2000)) 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 5377 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 VIN W (2000)) 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 5378 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 VIN W (2000)) 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 5379 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 VIN W (2000)) 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 5380 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 VIN W (2000)) 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 5381 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 VIN W (2000)) 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 5382 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 VIN W (2000)) 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 VIN W (2000)) 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 5388 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 VIN W (2000)) 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 5389 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 VIN W (2000)) 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 5390 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 VIN W (2000)) 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 5391 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 VIN W (2000)) 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 5392 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 VIN W (2000)) 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 5393 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 VIN W (2000)) 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 5394 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 VIN W (2000)) 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 5395 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5400 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5401 Fuse: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5420 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5421 Fuse: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5426 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5427 Fuse Block: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Fuse Block: Connector Views Central Junction Box C120: Only component connectors with 5 pins or more and in-line connectors with 6 pins or more are illustrated. Battery Junction Box (BJB) C120: Only component connectors with 5 pins or more and in-line connectors with 6 pins or more are illustrated. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5447 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5448 Fuse Block: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Locations > Page 5455 Mini ISO Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5460 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5461 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5462 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5463 Multiple Junction Connector: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5464 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5465 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5466 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5467 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5468 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5469 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5470 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5471 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5472 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5473 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5474 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5475 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5476 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5477 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5478 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5479 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5480 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5481 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5482 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5483 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5484 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5485 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5486 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations POLICE POWER RELAY Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5490 Power Distribution Relay: Testing and Inspection POLICE POWER RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Locations > Page 5498 Mini ISO Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations POLICE POWER RELAY Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5502 Power Distribution Relay: Testing and Inspection POLICE POWER RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5507 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5508 Relay Box: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5509 Relay Box: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5510 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5513 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5514 Relay Box: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5519 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5520 Relay Box: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5521 Relay Box: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5522 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5525 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5526 Relay Box: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5531 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5532 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5533 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5534 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5535 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5536 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5537 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5538 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5539 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5545 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5546 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 5547 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 5572 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 VIN W (2000)) 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 5573 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 VIN W (2000)) 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 5574 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 VIN W (2000)) 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 5575 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 VIN W (2000)) 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 5576 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 VIN W (2000)) 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 5577 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 VIN W (2000)) 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 5578 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 VIN W (2000)) 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 5579 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 VIN W (2000)) 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 VIN W (2000)) 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 5585 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 VIN W (2000)) 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 5586 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 VIN W (2000)) 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 5587 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 VIN W (2000)) 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 5588 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 VIN W (2000)) 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 5589 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 VIN W (2000)) 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 5590 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 VIN W (2000)) 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 5591 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 VIN W (2000)) 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 5592 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5597 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5598 Fuse: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5617 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5618 Fuse: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5623 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5624 Fuse Block: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 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 VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Fuse Block: Connector Views Central Junction Box C120: Only component connectors with 5 pins or more and in-line connectors with 6 pins or more are illustrated. Battery Junction Box (BJB) C120: Only component connectors with 5 pins or more and in-line connectors with 6 pins or more are illustrated. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5644 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5645 Fuse Block: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Locations > Page 5652 Mini ISO Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5657 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5658 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5659 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5660 Multiple Junction Connector: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5661 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5662 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5663 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5664 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5665 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5666 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5667 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5668 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5669 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5670 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5671 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5672 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5673 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5674 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5675 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5676 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5677 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5678 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5679 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5680 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5681 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5682 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C102 > Page 5683 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations POLICE POWER RELAY Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5687 Power Distribution Relay: Testing and Inspection POLICE POWER RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Locations > Page 5695 Mini ISO Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations POLICE POWER RELAY Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5699 Power Distribution Relay: Testing and Inspection POLICE POWER RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5704 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5705 Relay Box: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5706 Relay Box: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5707 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5710 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5711 Relay Box: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5716 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5717 Relay Box: Locations Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5718 Relay Box: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5719 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5722 Note: The battery junction box is located in the engine compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5723 Relay Box: Application and ID Central Junction Box Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5728 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5729 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5730 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5731 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5732 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5733 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5734 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5735 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 5736 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications Caster LH 5.5 +/- 0.75 deg RH 5.5 +/- 0.75 deg Total/Split 0.5 +/- 0.75 deg Camber LH -0.50 +/- 0.75 deg RH -0.50 +/- 0.75 deg Total/Split 0 +/- 0.75 deg Toe Total/Split -0.125 +/- 0.25 deg Toe @ curb ride height (positive value is toe-in, negative value is toe-out) Clear Vision -2.0 +/- 3 deg Negative value is counterclockwise Ride Height Base Front 1.2 +/- 0.5 in Rear 5.4 +/-0.3 in Ride Height Air Suspension Front 1.1 +/- 0.5 in Rear 5.2 +/- 0.3 in Ride Height Handling Package Front 1.0 +/- 0.5 in Rear 5.2 +/- 0.3 in Ride Height Police/NGV Front 1.0 +/- 0.5 in Rear 5.2 +/- 0.3 in Ball Joint Lateral Backlash Lower Ball Joint Max. 0.03937 in Upper Ball Joint Max 0.015 in Ball Joint End Play Lower Ball Joint Max 0.02 in Upper Ball Joint Max 0.02 in Vehicle Lean Front Wheel Opening Max 0.5 in Side to Side height differences Rear wheel Opening Max 0.5 in Camber and Caster Adjustment Nuts 129 ft lb Adjusting Sleeve Clamp Nuts 21 ft lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5743 Alignment: Description and Operation Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications provided will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5744 Alignment: Description and Operation Dogtracking 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5745 Alignment: Description and Operation 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). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5746 Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications provided will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Dogtracking Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5747 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. 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). General Information Wheel Alignment Angles ^ 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 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. 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 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 roadability problem, it is important to understand the difference between wander and poor groove feel. 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. Ride Height Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5748 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 scan tool. 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. Toe Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5749 Positive Toe (Toe In) Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel (3600) corrections to maintain a straight path down a level road. Wheel Track Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 5752 Alignment: Service and Repair Toe Adjustment 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Locations Air Suspension/Electronic Variable Orifice Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module > Page 5759 Steering Control Module: Locations Electronic Variable Orifice (EVO) Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5760 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5761 Steering Control 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 5766 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 5767 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 5768 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Rear Air Suspension Control Module Screws 20-29 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 5772 Suspension Control Module: Locations Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 5773 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 5774 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 5775 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 charts. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 5776 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 5786 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5787 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5788 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5789 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 5794 Ride Height Sensor: Description and Operation HEIGHT CONTROL SWITCH/SENSOR (LEVEL CONTROL) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 5795 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 5800 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5801 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5802 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5803 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 VIN W (2000)) 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 SUSPENSION SWITCH 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 VIN W (2000)) 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 5807 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications Sector Shaft Arm To Drag Link Nut 56 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Removal Center Link: Service and Repair Removal 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. 5. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Removal > Page 5814 6. Remove the nut. 1 Remove the cotter pin. 2 Remove the nut and washer. 7. Remove the steering sector shaft arm drag link. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Removal > Page 5815 Center Link: Service and Repair Installation 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. 3. Install the steering i!ear 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 5816 Center Link: Tools and Equipment Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations Diagnostic Connector: Locations Right hand side of luggage compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations > Page 5820 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: 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 as specified 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5824 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5825 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5826 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5827 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5828 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair > Installation Idler Arm: Service and Repair Installation Installation 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair > Installation > Page 5833 Idler Arm: Service and Repair Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Removal Pitman Arm: Service and Repair Removal 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Removal > Page 5840 Pitman Arm: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 5841 Pitman Arm: Tools and Equipment Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Purging 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 5846 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 5847 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 rive 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 rive 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 5848 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 5853 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5854 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Removal Power Steering Fluid Cooler: Service and Repair Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Removal > Page 5859 Power Steering Fluid Cooler: Service and Repair Installation Installation 1. Follow the removal procedure in reverse order. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Removal Power Steering Fluid Reservoir: Service and Repair Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Removal > Page 5864 Power Steering Fluid Reservoir: Service and Repair Installation Installation 1. Follow the removal procedure in reverse order. 2. Fill and leak check the system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Removal Power Steering Line/Hose: Service and Repair Removal Removal 1. Refer to the System View illustration for the hose routing and retention points. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Removal > Page 5869 Power Steering Line/Hose: Service and Repair Installation Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 5870 Power Steering Line/Hose: Tools and Equipment Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Power Steering Pump Bolts 18 ft.lb Pressure Fitting at Steering Pump 30 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5874 Power Steering Pump: Application and ID Power Steering Pump Identification 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 VIN W (2000)) 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 Removal Removal All Vehicles 1. Remove the drive belt. 2. Raise the vehicle. 3. Remove the routing bracket. Vehicles With EVO Steering System 4. Disconnect the power steering auxiliary actuator electrical connector. All Vehicles 5. Remove the pulley. 6. Disconnect the hose. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5877 7. Disconnect the hose. 8. Remove the four bolts and the power steering pump. Vehicles With EVO Steering System 9. If the power steering pump is to be replaced, remove the power steering auxiliary actuator. Installation Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5878 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5879 Power Steering Pump: Service and Repair Power Steering Pump Pulley Removal 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 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 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 5880 Power Steering Pump: Tools and Equipment Pulley-Pump Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Specifications Power Steering Valve: Specifications Power Steering Auxiliary Actuator 13 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Service and Repair > Removal Power Steering Valve: Service and Repair Removal 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Service and Repair > Removal > Page 5886 Power Steering Valve: Service and Repair Installation Installation 1. Follow the removal procedure in reverse order. 2. Fill and check the system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Locations Air Suspension/Electronic Variable Orifice Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module > Page 5891 Steering Control Module: Locations Electronic Variable Orifice (EVO) Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 5892 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 5893 Steering Control 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Locations Air Suspension/Electronic Variable Orifice Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Air Suspension/Electronic Variable Orifice Steering Module > Page 5899 Steering Control Module: Locations Electronic Variable Orifice (EVO) Steering Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5900 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5901 Steering Control 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch Power Steering Pressure (PSP) Switch The Power Steering Pressure (PSP) switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust transmission Electronic Pressure Control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 5910 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5911 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5912 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5913 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 5918 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5919 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5920 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5921 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5927 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5928 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5929 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5930 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5931 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder Steering Column Lock: Service and Repair Functional Lock Cylinder Removal 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 Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder > Page 5936 Steering Column Lock: Service and Repair Non-Functional Lock Cylinder Removal 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. 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. 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. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder > Page 5937 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 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder > Page 5938 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. 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: The narrow section of the keyhole in the lock gear must be in the one o'clock position. 1. Install the steering column lock gear and bearing. ^ Use Ignition Lock Grease F0AZ-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. 2. Install the bearing retainer firmly to engage the four retention tabs into the lock housing. 3. Install the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Functional Lock Cylinder > Page 5939 4. Install the ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Steering Gear Meshload 12-16 in.lb Ball Guide Clamp Bolts 53 in.lb Power Steering Gear Race Nut 73 ft.lb Steering Gear Race Setscrews 18 in.lb Steering Gear Bolts 58 ft.lb Mesh Load Adjuster Lock Nut 23 ft.lb Sector Shaft Housing Bolts 50 ft.lb Valve Housing Bolts 37 ft.lb Fittings at Steering Gear 15 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5943 Steering Gear: Application and ID Power Steering Gear Identification 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5944 Steering Gear: Testing and Inspection Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. 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. 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. 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 (50-200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard, or a strong shudder is felt, fill and purge the power steering system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5945 Steering Gear: Adjustments Meshload Adjustment Special Service Tool(s) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5946 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5947 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation Steering Gear: Service and Repair Removal and Installation Removal 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 (3B676) from the steering gear. 5. Disconnect the lines. 6. Raise the vehicle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5950 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 Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5951 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5952 Steering Gear: Service and Repair Disassembly and Assembly Disassembly 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5953 4. Tap on the lower end of the steering gear sector shaft (3575). 5. Remove the steering gear sector shaft. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5954 8. Remove the valve housing bolts and the identification tag. 9. Remove the valve housing and piston assembly. 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 (3544). 3 Remove the steering gear ball return guide (3523). 4 Rotate the piston over a container to collect the 27-29 ball bearing. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5955 12. Remove the input shaft valve and housing assembly from the piston. 13. Remove and discard the seal. 14. Install the valve housing in the special tool and loosen the setscrew. 15. Using the special tool, remove the race nut. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5956 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 (3D526) out of the valve housing. 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 (3548) in special tool 307-003 (T57L-500-B). Remove the steering gear sector shaft dust seal from the sector shaft seal bore. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5957 23. Remove the spacer. 1 Remove the snap ring. 2 Remove the spacer. 24. Note: The steering gear sector shaft bearing is not replaceable. Using the special tool, remove the sector shaft seal. Assembly Assembly 1. Lubricate the sector shaft seal bore. ^ Use Multipurpose Grease D0AZ-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 Multipurpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5958 3. Install the spacer. 4. Install the snap ring. 5. Note: Place the steering gear sector shaft dust seal on the special toot 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 Multipurpose Grease D0AZ-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 Multipurpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5959 8. Using the special tool, and a press, seat the power steering gear input shaft seal. 9. Install the input shaft snap ring. 10. Apply a liberal amount of Multipurpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5960 12. Mount the valve housing in the special tool. 13. Install the power steering gear input shaft and control into the valve housing. 14. Position the power steering gear race nut into the valve housing. 15. Using the special tool, tighten the race nut. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5961 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5962 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. 21. Install a new seal ring. 22. Lubricate and install the seal on the piston. ^ Use Multipurpose Grease D0AZ-19584-AA 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5963 24. Rotate the teeth so they are on the same plane as the steering gear sector shaft. 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 Multipurpose Grease D0AZ-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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5964 28. Install the sector shaft lock nut. The sector shaft lock nut will be tightened during the steering gear meshload adjustment. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Tools and Equipment > Disassembly and Assembly Steering Gear: Tools and Equipment Disassembly and Assembly Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Tools and Equipment > Disassembly and Assembly > Page 5967 Steering Gear: Tools and Equipment Special Service Tool Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 5976 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 5982 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5983 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. 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. 4. Remove and discard the steering wheel bolt. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5984 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 VIN W (2000)) 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 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. 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 Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 5990 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 5991 Tie Rod End: Service and Repair Outer Removal 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. 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 Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 5992 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 5993 Tie Rod End: Tools and Equipment Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Front Lower Ball Joint 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 Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5998 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 VIN W (2000)) 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 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. 1. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 6001 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 6002 Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint 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 Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 6003 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 VIN W (2000)) 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 Ball Joint-Lower Special Tools Special Tool(s) Removal and Installation 1. Remove the wheel and tire assembly. 2. Remove the disc brake caliper (2B120). Remove two front disc brakes caliper bolts. Lift the disc brake caliper off the front disc brake caliper anchor plate (2B292). Position caliper aside. 3. Remove the pads and stainless steel slippers. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6006 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 (3105). 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. Disconnect the lower ball joint from the front wheel spindle. Loosen the nut, leaving at lease three threads engaged in the ball joint. Using a hammer, sharply rap on the front wheel spindle until the lower ball joint disconnects from the spindlendle 7. Place a suitable jack stand under the front suspension lower arm (3078). Lower the vehicle until the front suspension lower arm begins to move. 8. Remove the ABS sensor Remove the bolt. Remove the ABS sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6007 9. Remove the stabilizer bar link (5K484) from the front wheel spindle. Remove the nut. 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. Remove the pinch bolt and nut. Raise the front suspension upper arm (3083). Remove the front wheel spindle. 12. Remove the discard the ball joint dust boot. 13. Using the special tools, press the ball joint from the suspension lower arm (3078). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6008 14. 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. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6009 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6010 1. To install, reverse the removal procedure. 2. Check wheel alignment. Adjust as necessary. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Page 6011 Ball Joint: Tools and Equipment Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 6020 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 6021 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 VIN W (2000)) 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 6022 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 VIN W (2000)) 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 6023 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 VIN W (2000)) 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 6024 ^ 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 VIN W (2000)) 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 6025 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 VIN W (2000)) 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 6026 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 VIN W (2000)) 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 6027 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 VIN W (2000)) 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 6028 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 VIN W (2000)) 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 6029 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 VIN W (2000)) 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 6030 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 6031 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 6037 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 6038 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 VIN W (2000)) 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 6039 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 VIN W (2000)) 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 6040 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 VIN W (2000)) 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 6041 ^ 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 VIN W (2000)) 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 6042 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 VIN W (2000)) 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 6043 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 VIN W (2000)) 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 6044 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 VIN W (2000)) 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 6045 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 VIN W (2000)) 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 6046 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 VIN W (2000)) 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 6047 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 6048 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 as specified 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6051 7. Using the special tool, remove the front suspension lower arm. Installation 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 as specified during reassembly to ensure proper retention of these parts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6052 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. To install, reverse the removal procedure. 2. Check wheel alignment. Adjust if necessary. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6053 Control Arm: Service and Repair Rear Suspension Lower Arm 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 as specified during reassembly to ensure proper retention of these parts. Vehicles Equipped With Air Suspension 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. All Vehicles 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 014-00942 or equivalent to support the rear axle. Vehicles Equipped With Air Suspension 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. All Vehicles Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6054 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 All Vehicles 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6055 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 014-00942 or equivalent. 7. Lower the vehicle. Vehicles Equipped With Air Suspension 8. Turn the air suspension service switch on. 9. Inflate the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6056 Upper Arm 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 as specified during reassembly to ensure proper retention of these parts. Vehicles Equipped With Air Suspension 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. All Vehicles 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 014-00942 or equivalent to support the rear axle. Vehicles Equipped With Air Suspension 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. All Vehicles Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6057 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. 7. Remove and discard the rear suspension upper arm pivot bolt and nut from the frame bracket. Remove the rear suspension upper arm. Installation All Vehicles 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6058 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 the special tool 014-00942 or equivalent. 7. Lower the vehicle. Vehicles Equipped With Air Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6059 8. Turn the air suspension service switch on. 9. Inflate the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Tools and Equipment > Front Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Tools and Equipment > Front Suspension > Page 6062 Rear Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: 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 as specified 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 6066 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 6067 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 6068 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 6069 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 6070 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications Torque Specification Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6074 Lateral Stabilizer Rod: Description and Operation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6075 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6076 The rear suspension is composed of the following: ^ Upper suspension arms ^ Lower suspension arms ^ Lateral arm ^ Watts link pivot ^ Rear stabilizer bar ^ Air springs (Air suspension systems only) ^ Coil springs (Non air suspension systems only) 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 as specified during reassembly to ensure proper retention of these parts. Orientation of the fasteners is also important on all suspension arms. Make sure the fasteners are installed in the same direction as when removed. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation Lateral Stabilizer Rod: Service and Repair Removal and Installation 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 as specified during reassembly to ensure proper retention of these parts. Vehicles Equipped With Air Suspension 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. All Vehicles 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 014-00942 or equivalent to support the rear axle. Vehicles Equipped With Air Suspension 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation > Page 6079 6. Disconnect the height sensor from the mounting bracket. All Vehicles 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation > Page 6080 10. Remove and discard the Watts link pivot stud. Installation All Vehicles 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation > Page 6081 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. Vehicles Equipped With Air Suspension 7. Connect the height sensor to the mounting bracket. All Vehicles Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation > Page 6082 8. Remove the special tool 014-00942 or equivalent. 9. Lower the vehicle. Vehicles Equipped With Air Suspension 10. Turn the air suspension service switch on. 11. Inflate the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation > Page 6083 Lateral Stabilizer Rod: Service and Repair Disassembly and Assembly 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 as specified during reassembly to ensure proper retention of these parts. All Vehicles 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. Vehicles Equipped With Air Suspension 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. All Vehicles Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal and Installation > Page 6084 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6089 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6090 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6091 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Rear Air Suspension Control Module Screws 20-29 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6095 Suspension Control Module: Locations Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6096 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6097 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6098 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 charts. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 6099 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 6104 Ride Height Sensor: Description and Operation HEIGHT CONTROL SWITCH/SENSOR (LEVEL CONTROL) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 6105 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Steering Angle Sensor > Page 6110 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6111 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6112 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6113 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 VIN W (2000)) 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 SUSPENSION SWITCH 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Description and Operation > Page 6117 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 VIN W (2000)) 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 as specified 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 VIN W (2000)) 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 as specified 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. 1 Position the stabilizer bar link. 2 Install the nut. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6126 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 6127 Stabilizer Link: Service and Repair Rear For information regarding the Service and Repair of this component and the system that it is a part of, please refer to Stabilizer Bar; Service and Repair; Rear Suspension. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications Air Dryer: Specifications Air Compressor Drier Hold Down Screw ............................................................................................................................................. 2-3 Nm (18-27 in-lb) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Page 6132 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 0-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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge Air Line: Service and Repair Air Line Fluid Purge Air Line Fluid Purge 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. Note: Perform this procedure if fluid (water and/or oil) is found in the air line. Purge fluid from rear air lines and replace affected components. Disconnect the air line at the air compressor drier. 2. Disconnect the air line from the air springs. 3. Connect a shop air line to the disconnected air line and blow any fluid out. 4. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air lines at the air springs. 5. Replace the air compressor drier. 6. Reconnect the air line to the air compressor drier. 7. Ensure that all air line fittings are sealed. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 6137 Air Line: Service and Repair Air Line Repair Air Line 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Page 6138 Air Line: Tools and Equipment Special Service Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure Air Spring: Service and Repair Air Spring Fill-Refold Procedure Air Spring Fill - Refold Procedure 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 6143 4. Install air spring solenoid to help maintain correct height. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 6144 Air Spring: Service and Repair Removal and Installation 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 following 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 uninvited 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 6145 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. 3. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 6146 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications Compressor/Pump: Specifications Air Compressor Bracket Bolts 68-88 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6150 Compressor/Pump: Description and Operation HEIGHT CONTROL SWITCH/SENSOR (LEVEL CONTROL) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6151 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 6152 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6156 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6157 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6158 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations > Page 6162 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation Level Control Solenoid Valve: 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve - Functional Level Control Solenoid Valve: Service and Repair Solenoid Valve - 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 counter-clockwise 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve - Functional > Page 6168 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve - Functional > Page 6169 Level Control Solenoid Valve: Service and Repair Solenoid Valve - 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve - Functional > Page 6170 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 6174 Ride Height Sensor: Description and Operation HEIGHT CONTROL SWITCH/SENSOR (LEVEL CONTROL) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 6175 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Rear Air Suspension Control Module Screws 20-29 in.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6179 Suspension Control Module: Locations Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6180 Suspension Control Module: Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6181 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6182 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 charts. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 6183 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 VIN W (2000)) 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 SUSPENSION SWITCH 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Description and Operation > Page 6187 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Warning Indicator > Component Information > Description and Operation > Page 6191 Suspension Warning Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Special Tool(s) 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 as specified during reassembly to ensure proper retention of these parts. 1. Mark the relative position of the front suspension lower arm (3078) 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6196 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6197 3. Make sure the front spring insulator is properly seated and remove the special tool 204-DO01 (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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6198 Suspension Spring ( Coil / Leaf ): Service and Repair Rear 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 as specified 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 014-00942 or equivalent to support the rear axle. 6. Remove the nuts and bolts and disconnect the lateral arms from the frame. Discard the nuts and bolts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6199 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6200 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). 8. Tighten both bolts. 9. Lower the axle and remove the special tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6201 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Tools and Equipment > Front Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Tools and Equipment > Front Suspension > Page 6204 Rear Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair Suspension Strut / Shock Absorber: Service and Repair 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 as specified during reassembly to ensure proper retention of these parts. Vehicles Equipped With Air Suspension 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. All Vehicles 2. Raise and support the vehicle. 3. Use the special tool 014-00942 or equivalent to support the rear axle. Vehicles Equipped With Air Suspension 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. All Vehicles Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Page 6208 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 All Vehicles 1. To install, reverse the removal procedure. Vehicles Equipped With Air Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Page 6209 2. Inflate the air springs. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Page 6210 Rear Suspension Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 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. 2. Spin the tire by hand to check the wheel bearings for roughness. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6216 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6217 Wheel Bearing: Testing and Inspection Wheel Bearing 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 6218 Wheel Bearing: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 6219 2. Using the special tool, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tool, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer 221 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 6233 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 VIN W (2000)) 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 6234 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 VIN W (2000)) 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 6235 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 VIN W (2000)) 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 6236 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 VIN W (2000)) 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 6237 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 VIN W (2000)) 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 6238 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 6239 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 6245 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 VIN W (2000)) 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 6246 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 VIN W (2000)) 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 6247 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 VIN W (2000)) 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 6248 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 VIN W (2000)) 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 6249 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 VIN W (2000)) 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 6250 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 6251 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6252 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. ^ Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6253 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 6254 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6259 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6260 Tires: 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6261 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6262 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6263 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6264 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6265 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 6266 Tires: Technical Service Bulletins Suspension - Repeated Tire Balancing Issues Article No. 00-26-7 12/25/00 ^ SUSPENSION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY - PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ WHEELS - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ VIBRATION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 FORD: 2000 CROWN VICTORIA This article is being republished in its entirety to update the build date coverage and Service Procedure. ISSUE Some 2000 model year Police Interceptors produced from 1/1/2000 through 8/14/2000 may have repeat issues with tire balance. This may be caused by tire slippage on the rim. ACTION Check for tire slippage on the rim using the following Service Procedure and if necessary, refer the customer to a Goodyear Service Center for tire service. SERVICE PROCEDURE Use the following procedure to test for tire slippage on the wheel. 1. Mark the tire and wheel for a reference location. 2. Conduct three (3) 80-0 km/h (50-0 mph) full stops with 1 kilometer (1 mile) cool down in between each run. 3. Inspect for slippage between the tire and wheel at the reference location. If no tire slippage is evident, balance the tires following the 2000 Crown Victoria Workshop Manual procedures. If tire slippage is evident, refer the customer to their local Goodyear Service Center for service. Goodyear has issued a Product Service Bulletin (PSB # 2000-48) which identifies the procedures to use to correct the issue. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-23-7 WARRANTY STATUS: Eligible Under The Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 306000, 703000, 703300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 6267 Tires: Specifications Wheels and Tires Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 6268 Tires: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias or bias-belted, on the same vehicle except in emergencies (temporary spare usage). Vehicle handleing can be seriously affected and can result in loss of control. Factory installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 VIN W (2000)) 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 VIN W (2000)) 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 6286 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > 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 6291 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > 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 6292 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > 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 6293 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > 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 6294 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > 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 6295 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-26-7 > Dec > 00 > Suspension - Repeated Tire Balancing Issues Wheels: All Technical Service Bulletins Suspension - Repeated Tire Balancing Issues Article No. 00-26-7 12/25/00 ^ SUSPENSION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY - PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ WHEELS - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ VIBRATION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 FORD: 2000 CROWN VICTORIA This article is being republished in its entirety to update the build date coverage and Service Procedure. ISSUE Some 2000 model year Police Interceptors produced from 1/1/2000 through 8/14/2000 may have repeat issues with tire balance. This may be caused by tire slippage on the rim. ACTION Check for tire slippage on the rim using the following Service Procedure and if necessary, refer the customer to a Goodyear Service Center for tire service. SERVICE PROCEDURE Use the following procedure to test for tire slippage on the wheel. 1. Mark the tire and wheel for a reference location. 2. Conduct three (3) 80-0 km/h (50-0 mph) full stops with 1 kilometer (1 mile) cool down in between each run. 3. Inspect for slippage between the tire and wheel at the reference location. If no tire slippage is evident, balance the tires following the 2000 Crown Victoria Workshop Manual procedures. If tire slippage is evident, refer the customer to their local Goodyear Service Center for service. Goodyear has issued a Product Service Bulletin (PSB # 2000-48) which identifies the procedures to use to correct the issue. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-23-7 WARRANTY STATUS: Eligible Under The Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 306000, 703000, 703300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 6305 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 VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 6310 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 6311 For Dealerships without An Electronic Vibration Analyzer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 6312 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 > Page 6313 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 VIN W (2000)) 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 > Page 6314 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-26-7 > Dec > 00 > Suspension - Repeated Tire Balancing Issues Wheels: All Technical Service Bulletins Suspension - Repeated Tire Balancing Issues Article No. 00-26-7 12/25/00 ^ SUSPENSION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY - PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ WHEELS - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 ^ VIBRATION - REPEAT TIRE BALANCE ISSUES - POLICE INTERCEPTOR VEHICLES ONLY PRODUCED 1/1/2000 THROUGH 8/14/2000 FORD: 2000 CROWN VICTORIA This article is being republished in its entirety to update the build date coverage and Service Procedure. ISSUE Some 2000 model year Police Interceptors produced from 1/1/2000 through 8/14/2000 may have repeat issues with tire balance. This may be caused by tire slippage on the rim. ACTION Check for tire slippage on the rim using the following Service Procedure and if necessary, refer the customer to a Goodyear Service Center for tire service. SERVICE PROCEDURE Use the following procedure to test for tire slippage on the wheel. 1. Mark the tire and wheel for a reference location. 2. Conduct three (3) 80-0 km/h (50-0 mph) full stops with 1 kilometer (1 mile) cool down in between each run. 3. Inspect for slippage between the tire and wheel at the reference location. If no tire slippage is evident, balance the tires following the 2000 Crown Victoria Workshop Manual procedures. If tire slippage is evident, refer the customer to their local Goodyear Service Center for service. Goodyear has issued a Product Service Bulletin (PSB # 2000-48) which identifies the procedures to use to correct the issue. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-23-7 WARRANTY STATUS: Eligible Under The Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 306000, 703000, 703300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6319 Wheels: Specifications Wheels and Tires Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire 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 beatings. 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 puffer 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 6322 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 6323 Wheels: Service and Repair Wheel Leaks WARNING: 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 installation of a new wheel. 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 a new wheel. 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-M14PI0-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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Page 6324 Wheels: Tools and Equipment Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 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. 2. Spin the tire by hand to check the wheel bearings for roughness. 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6330 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6331 Wheel Bearing: Testing and Inspection Wheel Bearing 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 6332 Wheel Bearing: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 6333 2. Using the special tool, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tool, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Wheel Hub Retainer 221 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nuts 85-105 ft.lb Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front 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. 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 VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 6343 Wheel Fastener: Service and Repair Rear Removal Vehicles Equipped With Air Suspension 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. All Vehicles 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. All Vehicles 1. Insert a new lug bolt in the hole in the axle flange, making sure serrations are aligned with those in the flange. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 6344 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. Vehicles Equipped With Air Suspension 8. Turn the air suspension service switch on. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 6345 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Accumulator Mounting Bracket Clamp Bolt 6-8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6350 Accumulator HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6351 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6352 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6353 Accumulator HVAC: Service Precautions CAUTION: - To prevent damage to the fitting and the tube, use a backup wrench when removing the suction accumulator/drier. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6354 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6355 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. Perform the Refrigerant Discharging and Recovery Procedure. 2. Disconnect the evaporator to compressor suction line from the suction accumulator/drier. Refer to spring lock couplings disconnect and connect general procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6356 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. See Refrigerant Oil Addition. - 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6357 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Manual A/C. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 6365 Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Connector Views Air Door Actuator / Motor: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Connector Views > Page 6368 Air Door Actuator / Motor: Vacuum and Vapor Hose Diagrams Vacuum Schematic - Manual A/C Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Connector Views > Page 6369 Vacuum Schematic - Electronic Automatic Temperature Control Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Motor 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Motor > Page 6372 Air Door Actuator / Motor: Description and Operation Air Door Actuator / Motor, HVAC With Manual A/C 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 6375 Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC Air Recirculation Door Vacuum Control Motor 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 6376 INSTALLATION 1. To install, reverse the removal procedure. Floor Duct Door Actuator 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. Panel/Defrost Door Vacuum Control Motor REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the LH lower dash insulator panel and disconnect the lamp. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 6377 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 6378 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Locations Air Distribution Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct Air Duct: Service and Repair Air Recirculating Duct REMOVAL 1. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the plenum chamber. For additional information, refer to 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6384 7. Remove the nut. 8. Remove the nut and position the harness cover aside. 9. Remove the nut. 10. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6385 11. Remove the wiring harness. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6386 Air Duct: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the screw and remove the bracket. 3. Disengage the in-car temperature sensor hose retainers. 4. Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6387 5. Remove the RH panel duct. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6388 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6389 Air Duct: Service and Repair Heater Outlet Floor Duct REMOVAL 1. Remove the rear seat airflow duct. For additional information, refer to Air 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Recirculating Duct > Page 6390 Air Duct: Service and Repair Rear Seat Airflow Duct REMOVAL 1. Remove the seats. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Passenger Side Air Register: Service and Repair Passenger Side REMOVAL 1. Remove the passenger side airbag. For additional information, refer to Air Bag Systems. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Passenger Side > Page 6395 Air Register: Service and Repair Driver Side and Center Register Radio Removal Tool SPECIAL SERVICE 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Passenger Side > Page 6396 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 6397 Radio Removal Tool Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6401 Control Components 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6402 Ambient Temperature Sensor / Switch HVAC: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6403 Ambient Temperature Sensor / Switch HVAC: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6412 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 04-24-14 > Dec > 04 > Customer Interest for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 04-24-14 > Dec > 04 > Customer Interest for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6422 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 01-1-6 > Jan > 01 > Component Information > Technical Service Bulletins > Customer Interest for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 01-1-6 > Jan > 01 > Component Information > Technical Service Bulletins > Customer Interest for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6433 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 01-1-6 > Jan > 01 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > 01-1-6 > Jan > 01 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Aspirator: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6439 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Aspirator: > Page 6440 Power Distribution Relay: Testing and Inspection POLICE POWER RELAY Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6449 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6455 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 6456 Blower Motor: Locations Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 6457 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Blower Motor: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Blower Motor: Electrical Diagrams EATC This article has been updated by Technical Service Bulletin (TSB) 00-11-2 dated May 29, 2000 Although the electrical diagrams for the blower motor can be found at the system level, if your vehicle has a blower motor stuck on high speed, insufficient air across the in car temperature sensor may be the cause. Check for TSBs. For the wiring, refer to Heating and Air Conditioning / Diagrams. See: Diagrams/Electrical Diagrams MTC The diagrams for this component can be found at the system level. Refer to Heating and Air Conditioning / Diagrams. See: Diagrams/Electrical Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Blower Motor: Vacuum and Vapor Hose Diagrams Vacuum Schematic - Manual A/C Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Vacuum Schematic - Electronic Automatic Temperature Control Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6477 Blower Motor: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6478 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6479 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6480 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 Blower Motor Relay: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6502 Blower Motor Resistor Location. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6503 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 6507 Blower Motor Switch: Service and Repair Removal 1. Remove the control assembly. For additional information, refer to Control Assembly in this section. See: Control AssemblySee Service and Repair. 2. Note: The knob will drop off as the function selector is removed. Remove the function selector. 1. Depress the snap tabs. 2. Remove the function selector. 3. Note: The knob Will drop off as the temperature blend control switch is removed. Remove the temperature blend control switch. 1. Remove the screw. 2. Rotate and pull the temperature blend control switch. 4. Note: The knob Will drop off as the blower motor switch is removed. Remove the blower motor switch. 1. Depress the snap tabs. 2. Remove the blower motor switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Behind top center of Instrument Panel (I/P) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6514 Cabin Temperature Sensor / Switch: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6515 Cabin Temperature Sensor / Switch: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6516 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air Gap between Pulley and Hub 0.35-0.85 mm A/C Compressor Clutch Retaining Bolt 11-14 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6521 A/C Compressor Clutch Assembly Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6522 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6523 Compressor Clutch: Description and Operation NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced 0n1y as an assembly. The A/C clutch,A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - 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 compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. The FS-10 A/C compressor has the following characteristics: - a 10-cylinder swashplate design utilizing the tangential design mount - displacement of 170 cc (10 cubic inch) - a one-piece lip-type seal (installed from the front of the A/C compressor) which is used to seal it at the shaft opening in the assembly - five double-acting pistons which operate within the cylinder assembly (The pistons are actuated by a swashplate that converts the rotating action of the shaft to a reciprocating force.) - reed-type discharge valves located between the cylinder assembly and the head at each end of the A/C compressor - uses PAG compressor oil YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B (This oil contains special additives required for the A/C compressor.) A/C Compressor Clutch Assembly The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. - The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch disc away from the A/C clutch pulley. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6524 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6525 Compressor Clutch: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C compressor. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6526 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6527 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6528 6. Install the A/C clutch. 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. A/C Compressor Clutch Assembly 9. Install the A/C compressor. For additional information, refer to Compressor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6529 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams A/C Compressor Clutch Assembly Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6533 Compressor Clutch Coil: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C compressor. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6534 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6535 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6536 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. A/C Compressor Clutch Assembly 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. For additional information, refer to Compressor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Diagrams A/C Compressor Clutch Assembly Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions Compressor Shaft Seal: Service Precautions CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6543 Compressor Shaft Seal: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. For additional information, refer to Clutch and Clutch Field Coil. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6544 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6545 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6546 5. Install the shaft seal snap ring with the sharp edge facing up. 6. Carry out the A/C compressor external leak test. See: Testing and Inspection 7. Install the shaft seal felt. 8. Install the A/C clutch. For additional information, refer to Clutch and Clutch Field Coil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 6547 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Compressor Clutch Relay: Customer Interest A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6556 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6557 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6558 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Compressor Clutch Relay: All Technical Service Bulletins A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6564 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6565 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6566 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > A/C WOT Cut-Out Relay (Gasoline) View 151-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > A/C WOT Cut-Out Relay (Gasoline) > Page 6569 View 151-4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6570 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6571 Compressor Clutch Relay: Description and Operation Wide Open Throttle A/C Cut-Off The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6572 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 6576 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 6577 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. Refer to the spring lock couplings disconnect and connect procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 5. Disconnect the evaporator to compressor suction line from the A/C manifold and tube. Refer to the spring lock couplings disconnect and connect procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 6. Loosen the bolt and remove the A/C manifold and tube. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 6578 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. - 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 6579 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 6580 Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condensor Core Mounting Bolts 8-11 Nm Compressor to Condenser Tube Bracket Retaining Nut 17-23 Nm Radiator mounting bracket retaining bolts 25-35 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6584 Condenser HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6585 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6586 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6587 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6588 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. For additional information, refer to Discharging and Recovery. See: Service and Repair/Refrigerant Discharging and Recovery procedure 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. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6589 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. Perform the Refrigerant Discharging and Recovery Procedure. 2. Remove the battery. For additional information, refer to Battery. 3. Remove the radiator upper sight shield. 4. Disconnect the condenser to evaporator tube from the A/C condenser core. Refer to the peanut fitting connect and disconnect general procedure. See: Coupler HVAC/Service and Repair/Peanut Fitting Connect and Disconnect Procedure 5. Disconnect the A/C compressor to condenser discharge line from the A/C condenser core. Refer to the peanut fitting connect and disconnect general procedure. See: Coupler HVAC/Service and Repair/Peanut Fitting Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6590 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6591 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. See Refrigerant Oil Addition. - 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6592 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6593 Special Tool(s) Set, A/C Fittings Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 6597 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Main Climate Control Control Assembly: Description and Operation Main Climate Control With Electronic Automatic Temperature Control (EATC) 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. With Manual A/C 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Main Climate Control > Page 6600 Control Assembly: Description and Operation With Manual A/C The manual climate control system heats or cools the vehicle interior depending on the function selector switch position and the temperature selected. The function selector position determines heating or cooling and air distribution. The temperature blend control setting determines air temperature The manual climate control system components are used to select: - air inlet source (outside or recirculated). - blower motor speed. - discharge air temperature (temperature blend). - discharge air location (defrost, panel, floor). - A/C compressor clutch operation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Page 6601 Control Assembly: Testing and Inspection For further information regarding this component please refer to : Heating and Air Conditioning; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control Control Assembly: Service and Repair Main Climate Control 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 6604 - Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 6605 Control Assembly: Service and Repair With Electronic Automatic Temperature Control 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. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Main Climate Control > Page 6606 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 6611 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page 6612 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Control Module HVAC: Locations Electronic Climate Control Module Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6615 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6616 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6617 Control Module HVAC: Locations Blower Motor Speed Control EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6618 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 6621 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module Control Module HVAC: Description and Operation Electronic Climate Control Module Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6624 With the use of a microcontroller, the Electronic Automatic Temperature Control (EATC) module analyzes input from the following major sources: - temperature, function and blower selection (made by the vehicle occupants) - in-vehicle temperature sensor - ambient temperature sensor - sunload sensor - vehicle speed sensor - engine coolant temperature sensor Using these inputs, the microcontroller determines the correct conditions for the following outputs: - A/C clutch engagement - blower speed - air temperature blend door position - floor/panel door position - panel/defrost door position - air inlet duct door position Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6625 Part 1 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6626 Part 2 Of 2 System Response a If engine coolant temperature fails to reach 50°C (122°F) after 3-1/2 minutes of operation, the heater blower motor speed will increase and the windshield defroster door will shift from defrost position to floor position. b The A/C system is enabled by the EATC control assembly, but final control of the A/C compressor clutch is determined by the Powertrain Control Module (PCM) through the use of a normally open clutch control relay. The A/C clutch can be shut off (or kept off) for several seconds at engine start-up, during high engine speeds, during low engine idle conditions (approximately 200 rpm below idle specs) and when the engine coolant temperature sensor reading exceeds approximately 120°C (248°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6627 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Page 6628 Control Module HVAC: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 6633 Spring Lock Coupling Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 6634 Coupler HVAC: Service Precautions 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. - 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. - Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. - Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. - Support the female fitting with a wrench to prevent the tubes from twisting. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling > Page 6637 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure Spring Lock Coupling Disconnect Tool Set SPECIAL SERVICE 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 lock coupling spring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 6640 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 6641 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 6642 CONNECT 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the O-ring seals. - Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 result in intermittent leakage during vehicle operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 6643 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 6644 Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 6645 2. Install the O-ring seal. - Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations Heating And Ventilation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6649 Evaporator Case: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 3. Drain the radiator so that the coolant level is below the heater core. For additional information, refer to Cooling System. 4. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6650 11. Disconnect the evaporator to compressor suction line from the suction accumulator drier. Refer to spring lock couplings disconnect and connect general procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 12. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube. Refer to spring lock couplings disconnect and connect general procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6651 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6652 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6653 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6654 4. Install the screw. 5. Install the screw. 6. Install the RH lower instrument panel insulator. 7. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Install the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6655 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6656 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-1 9553-A or equivalent meeting Ford specification ESF-M99B112-A. 18. Connect the evaporator compressor suction line to the suction accumulator/drier. Refer to spring lock couplings disconnect and connect general procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6657 19. Connect the condenser to evaporator tube. Refer to spring lock couplings disconnect and connect general procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 20. Connect the connector. 21. Install the blower motor switch resistor. 22. Connect the battery ground cable. 23. Fill the cooling system. For additional information, refer to Cooling System. 24. Evacuate and recharge the refrigerant system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6658 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Locations > Page 6659 Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations Evaporator Core: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6663 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6664 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6665 Evaporator Core: Diagrams Vacuum Schematic - Manual A/C Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6666 Vacuum Schematic - Electronic Automatic Temperature Control Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6667 Evaporator Core: Service Precautions 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6668 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6669 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. For additional information, refer to Discharging and Recovery. See: Service and Repair/Refrigerant Discharging and Recovery procedure 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. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6670 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. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6671 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. See Refrigerant Oil Addition. - 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6672 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Locations > Page 6673 Special Tool(s) Set, A/C Fittings Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6682 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6688 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications Expansion Block/Orifice Tube: Specifications Color Code Orange Orifice Diameter 1.46 mm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6692 Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6693 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6694 Expansion Block/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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6695 Expansion Block/Orifice Tube: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. For additional information, refer to Line-Condenser to Evaporator. - For an undamaged fixed orifice tube, perform Steps 2 and 3. - For a broken fixed 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6696 4. Screw the end of the Broken Orifice Extractor into the broken A/C evaporator core orifice. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6697 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube. For additional information, refer to Line-Condenser to Evaporator. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Specifications > Page 6698 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6710 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6711 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > 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 6717 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > 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 6718 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6719 Heating And Ventilation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6720 Heater Core: Diagrams Vacuum Schematic - Manual A/C Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6721 Vacuum Schematic - Electronic Automatic Temperature Control Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6722 Heater Core: Service Precautions 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. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6723 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6724 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6725 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 6726 Heater Core: Service and Repair 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. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair Heater Core Case: Service and Repair REMOVAL 1. Remove the rear seat airflow duct. For additional information, refer to Air Duct. 2. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Drain the coolant from the radiator so the coolant level is below the heater core. For additional information, refer to Cooling System. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 6730 7. Disconnect the vacuum hose. 8. Remove the pin-type retainers and remove the vacuum harness. 9. Disconnect the connector. 1O. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 6731 11. Disconnect the connectors. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 6732 3. Install the nut. 4. Install the in-car temperature sensor hose (if equipped). 5. Install the connector. 6. Install the vacuum harness. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 6733 7. Connect the vacuum hose. 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. For additional information, refer to Cooling System. 11. Install the heater outlet floor duct. For additional information, refer to Heater Outlet Floor-Duct. 12. Install the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 6742 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 VIN W (2000)) 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 6743 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 VIN W (2000)) 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 VIN W (2000)) 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 6749 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 VIN W (2000)) 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 6750 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 6751 Heating And Ventilation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 6752 Heater Hose: Service and Repair REMOVAL 1. Drain the radiator. For additional information, refer to Cooling System. 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 VIN W (2000)) 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 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Mechanical Specifications > Page 6757 High Pressure Safety Valve HVAC: Pressure, Vacuum and Temperature Specifications Open 3103 kPa Minimum Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 6758 High Pressure Safety Valve HVAC: Locations Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 6759 Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 6760 High Pressure Safety Valve HVAC: Description and Operation 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 6761 High Pressure Safety Valve HVAC: Service and Repair REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Remove the A/C compressor pressure relief valve. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Peanut Fitting Nut 7 - 9 Nm Peanut Fitting Retaining Nut 7 - 9 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 6765 Hose/Line 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 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 VIN W (2000)) 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. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. For additional information refer to the spring lock couplings disconnect and connect procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 6768 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 6769 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. For additional information refer to the spring lock couplings disconnect and connect procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 6770 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 6771 Hose/Line HVAC: Service and Repair Condenser to Evaporator Line REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Disconnect the condenser to evaporator tube from the A/C evaporator core. For additional information refer to the spring lock couplings disconnect and connect general procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 6772 Hose/Line HVAC: Service and Repair Evaporator to Compressor Suction Line REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 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. For additional information, refer to the spring lock couplings disconnect and connect procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 6. Disconnect and remove the evaporator to compressor suction line from the A/C manifold and tube assembly. For additional information, refer to Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 6773 the spring lock couplings disconnect and connect procedure. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 6774 Spring Lock Coupling Disconnect Tool Set Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations Air Distribution Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 6778 Housing Assembly HVAC: Service and Repair REMOVAL 1. Remove the rear seat airflow duct. For additional information, refer to Air Duct. See: Air Duct/Service and Repair 2. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Drain the coolant from the radiator so the coolant level is below the heater core. For additional information, refer to Cooling System. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 6779 7. Disconnect the vacuum hose. 8. Remove the pin-type retainers and remove the vacuum harness. 9. Disconnect the connector. 1O. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 6780 11. Disconnect the connectors. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 6781 3. Install the nut. 4. Install the in-car temperature sensor hose (if equipped). 5. Install the connector. 6. Install the vacuum harness. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 6782 7. Connect the vacuum hose. 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. For additional information, refer to Cooling System. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 11. Install the heater outlet floor duct. For additional information, refer to Heater Outlet Floor-Duct. 12. Install the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6787 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6788 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6789 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6790 ^ 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Ford Designation Specification R134a Refrigerant YN-19 WSH-M17B19-A System Capacity 38 oz (US) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6793 Refrigerant: Fluid Type Specifications R-134a Refrigerant Ford Part Number................................................................................................................................. ...................................................Motorcraft YN-19 Ford Specification................................................................................................................................. ....................................................WSH-M17B19-A Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6794 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6795 Fax: 215-541-4635 http://www.macsw.org/ Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6796 Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure SPECIAL SERVICE TOOL(S) 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing. See: Testing and Inspection/Component Tests and General Diagnostics/Identifying Refrigerants 2. Connect the R-134a A/C Refrigerant Center to the low- and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. See: Service and Repair/Manifold Gauge Set Connection 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the refrigerant center has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the refrigerant center hose(s). 6. If the system pressure rises, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repair operations, then evacuate and recharge the A/C system. For additional information, refer to Evacuation and Charging. See: Service and Repair/Evacuation and Charging Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Ford Designation Specification Motorcraft (R) Part # PAG Refrigerant Compressor Oil YN-12-C WSH-M1C231-B F7AZ-19589-DA System Capacity 207 mL Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6801 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) Ford Part Number................................................................................................................................. ................F7AZ-19589-DA (Motorcraft YN-12-C) Ford Specification................................................................................................................................. ...................................................WSH-M1C231-B Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6802 Refrigerant Oil: Service and Repair Refrigerant Oil Addition CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting the oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: New A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 0.5 in (12.5 mm) holes in the suction accumulator/drier cylinder and drain the oil into a calibrated Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6803 container. Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice - installation of a new A/C compressor pressure relief valve - installation of a new refrigerant line - repair of an O-ring seal leak - repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch, the A/C pressure cut-off switch and the A/C pressure transducer do not require additional oil. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Refrigerant Pressure Sensor / Switch: Customer Interest A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6812 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6813 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6814 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6820 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6821 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6822 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 6825 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications Compressor Clutch Cycling Switch Closes at: 276-324 kPa Opens at: 152-193 kPa Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6826 Refrigerant Pressure Sensor / Switch: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6827 Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6828 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6829 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 6832 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling 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. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - (SCP) communication. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 6833 Air Conditioning High Pressure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Compressor Cut-Off/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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 6836 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Blower Motor Relay: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Compressor Clutch Relay: Customer Interest A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6864 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6865 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6866 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Compressor Clutch Relay: All Technical Service Bulletins A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6872 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6873 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Relay: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6874 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C WOT Cut-Out Relay (Gasoline) View 151-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > A/C WOT Cut-Out Relay (Gasoline) > Page 6877 View 151-4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6878 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6879 Compressor Clutch Relay: Description and Operation Wide Open Throttle A/C Cut-Off The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6880 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 6885 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 VIN W (2000)) 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 6886 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Control Module HVAC: Locations Electronic Climate Control Module Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6889 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6890 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6891 Control Module HVAC: Locations Blower Motor Speed Control EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 6892 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 6895 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module Control Module HVAC: Description and Operation Electronic Climate Control Module Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6898 With the use of a microcontroller, the Electronic Automatic Temperature Control (EATC) module analyzes input from the following major sources: - temperature, function and blower selection (made by the vehicle occupants) - in-vehicle temperature sensor - ambient temperature sensor - sunload sensor - vehicle speed sensor - engine coolant temperature sensor Using these inputs, the microcontroller determines the correct conditions for the following outputs: - A/C clutch engagement - blower speed - air temperature blend door position - floor/panel door position - panel/defrost door position - air inlet duct door position Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6899 Part 1 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6900 Part 2 Of 2 System Response a If engine coolant temperature fails to reach 50°C (122°F) after 3-1/2 minutes of operation, the heater blower motor speed will increase and the windshield defroster door will shift from defrost position to floor position. b The A/C system is enabled by the EATC control assembly, but final control of the A/C compressor clutch is determined by the Powertrain Control Module (PCM) through the use of a normally open clutch control relay. The A/C clutch can be shut off (or kept off) for several seconds at engine start-up, during high engine speeds, during low engine idle conditions (approximately 200 rpm below idle specs) and when the engine coolant temperature sensor reading exceeds approximately 120°C (248°F). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Electronic Climate Control Module > Page 6901 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Page 6902 Control Module HVAC: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Manual A/C. 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6910 Control Components 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6911 Ambient Temperature Sensor / Switch HVAC: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6912 Ambient Temperature Sensor / Switch HVAC: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6916 Blower Motor Switch: Service and Repair Removal 1. Remove the control assembly. For additional information, refer to Control Assembly in this section. See: Control AssemblySee Service and Repair. 2. Note: The knob will drop off as the function selector is removed. Remove the function selector. 1. Depress the snap tabs. 2. Remove the function selector. 3. Note: The knob Will drop off as the temperature blend control switch is removed. Remove the temperature blend control switch. 1. Remove the screw. 2. Rotate and pull the temperature blend control switch. 4. Note: The knob Will drop off as the blower motor switch is removed. Remove the blower motor switch. 1. Depress the snap tabs. 2. Remove the blower motor switch. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Behind top center of Instrument Panel (I/P) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6920 Cabin Temperature Sensor / Switch: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6921 Cabin Temperature Sensor / Switch: 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6922 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6931 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH Technical Service Bulletin # 00-11-2 Date: 000529 EATC - No Setpoint/Blower Stays on HIGH Article No. 00-11-2 May 29, 2000 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH - EATC VEHICLES ONLY ^ AIR CONDITIONING - TEMPERATURE DOES NOT MAINTAIN SETPOINT - EATC VEHICLES ONLY FORD: 2000 CROWN VICTORIA, TAURUS 1999-2000 EXPLORER LINCOLN: 2000 LS, TOWN CAR MERCURY: 2000 GRAND MARQUIS, SABLE 1999-2000 MOUNTAINEER ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), there may be concerns where the blower motor may stay on high after desired temperature is reached, where temperature control does not maintain setpoint, and/or where the temperature gradually wanders away from the setpoint. ACTION Refer to the following Service Procedure to aid in normal diagnostics of the EATC system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208200, 208300, 208999 Service Procedure If no Diagnostic Trouble Codes (DTCs) are obtained during the EATC/DATC module self-test, refer to the following diagnostic Service Procedure. 1. Inspect the in-car temperature sensor aspirator hose for proper connections at both ends. 2. Inspect the aspirator hose for kinks or cuts. 3. On applicable vehicles, verify that the in-car temperature sensor is attached and firmly seated to the dash panel. Some vehicles mount the sensor on two pins located on the dash panel. The sensor may be mounted onto the pins loosely and not seated firmly against the dash panel, causing a gap in the sensor-to-dash panel seal and allowing warm air from behind the instrument panel to be drawn across the sensor. 4. Explorer/Mountaineer Only: Check the mounting fasteners to verify that the gap in the fastener is facing horizontally (i.e., at 3 or 9 o'clock). If the gap in the fastener is facing vertically (i.e., 6 or 12 o'clock), the sensor will require greater pressure to seat firmly against the instrument panel. NOTE: A LOOSELY MOUNTED IN-CAR TEMPERATURE SENSOR, OR ASPIRATOR HOSE WITH CUTS OR KINKS MAY CAUSE SYSTEM TO BE UNABLE TO MAINTAIN SETPOINT TEMPERATURE OR SETPOINT IS REACHED BUT SYSTEM GRADUALLY COOLS. EATC/DATC Aspiration Test This test will determine if the in-car temperature sensor is receiving enough aspiration. A lack of aspiration may result in an incorrect in-car temperature sensor reading and may cause the EATC/DATC system to act erratically and/or EATC/DATC blowing too cold or too warm. 1. Cut a piece of toilet tissue or tissue paper about 2.5 x 2.5 cm (1" x 1"). NOTE: PAPER TOWEL WILL NOT WORK CORRECTLY. 2. Turn key on, fan speed to HIGH BLOWER, and select PANEL or VENT mode. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 00-11-2 > May > 00 > EATC - No Setpoint/Blower Stays on HIGH > Page 6937 3. Place the piece of tissue paper over the aspirator grille opening. If aspiration (suction) is present, the tissue paper should stick to the grille. 4. Slowly lower the fan speed to LOW BLOWER. The tissue should continue sticking to the grille. 5. Turn the fan speed to HIGH BLOWER, then to OFF. Tissue paper should fall off the grille. 6. If the tissue paper falls off the aspirator grille when the blower fan is on in any speed: a. Verify that the aspirator hose is properly connected at both ends. Check the aspirator hose for kinks or cuts. b. Verify that the in-car temperature sensor is properly installed/sealed against the dash panel. c. Repair as required. 7. On vehicles equipped with a coolant control valve, check for proper operation of the coolant control valve. Visually inspect vacuum hoses for kinks, leaks, or disconnects. 8. Temperature differentials between panel/floor/defrost vents in mix modes and temperature setpoints that are not at full cool or full heat may exist and are considered normal and not repairable. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Refrigerant Pressure Sensor / Switch: Customer Interest A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6946 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6947 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6948 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Lack of Cooling/Restricted Air Flow From Vents TSB 04-19-11 09/22/04 LACK OF A/C COOLING - RESTRICTED/REDUCED AIR FLOW THROUGH VENTS EVAPORATOR CORE ICING FORD: 2000-2004 Crown Victoria MERCURY: 2000-2004 Grand Marquis This article supersedes TSB 03-22-8 to update the part information. ISSUE Some vehicles may exhibit a lack of A/C cooling and restricted/reduced air flow through the A/C vents typically during extended idling conditions. This may be due to extended A/C compressor operation (lack of compressor cycling) causing icing of the evaporator core surface. ACTION To service, first verify that the A/C clutch relay is operating properly and that the contacts are not sticking closed. The A/C clutch relay contacts may stick closed due to arcing. The arcing may be caused by transient voltage from the A/C clutch field coil when the relay contacts open to turn off the AC clutch. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Monitor the powertrain control module (PCM) PIDS ACCS, WAC and high/low side refrigerant pressures. If WAC PID reads OFF, and the A/C compressor continuously operates, check for A/C Relay contacts sticking closed. a. A/C relay contacts that are sticking closed will have continuity between relay pins 30 and 87. If continuity is found replace the A/C relay (2000-2002 FOAZ-14N089-A or 2003-2004 F5TZ-14N089-B). It will also be necessary to add a 400V 1.0A Diode (E8DZ-10C912-A) from circuit 57 BK to circuit 321 GY/WH. (SEE DIODE INSTALLATION BELOW). b. If the A/C relay contacts are not sticking closed, then do not continue with this TSB. Perform normal diagnosis using wiring diagrams and Workshop Manual procedures. 2. If the ACCS PID reads ON with low side refrigerant pressures below 20 PSI, diagnose for a faulty cycling switch or shorted circuits. NOTE FOR 2003-2004 MODEL YEAR, CYCLING OF THE A/C COMPRESSOR IS CONTROLLED BY A THERMISTOR SIGNAL TO THE PCM. THE LOW PRESSURE CYCLING SWITCH IS ONLY FOR SYSTEM PROTECTION. a. On 2000-2002 model years the low pressure cycling switch was used to control system operation. For these model years replacement of the low pressure cycling with one that has a higher set point can also reduce the potential for ice build up on the evaporator core. For 2000-2002 model years only, replace the white A/C low pressure cycling switch with black low pressure cycling switch (F5VY-19E561-A) per Workshop Manual Section 412-03. DIODE INSTALLATION NOTE PICTURED ON THE DIODE WILL BE AN ARROW WITH A LINE AT THE TIP (THE SYMBOL FOR THE DIODE). THIS IS IMPORTANT TO NOTE BECAUSE IT INDICATES THE DIRECTION IN WHICH THE DIODE MUST BE INSTALLED. THE DIODE MUST BE PLACED SO THAT THE ARROW POINTS FROM CIRCUIT 57 BK TO CIRCUIT 321 GY/WH. REFER TO THE DIODE INSTALLATION PROCEDURES BELOW. 1. Disconnect the battery positive terminal. 2. Disconnect female connector C128 (2000-2001 model years) or female connector C1033 (2002-2004 model years) on the engine harness. 3. Identify circuit 57 (BK) pin location 10 and circuit 321 (GY/WH) pin location 7 (pin location 8 on Natural Gas Vehicle (NGV)). 4. Remove circuits 57 and 321 from the connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6954 5. Strip 25 mm (1") of insulation away from circuit 57 approximately 50 mm (2") from the connector (Figure 1). 6. Strip 25 mm (1") of insulation away from circuit 321 approximately 100 mm (4") from the connector (Figure 1). 7. Cut the butt connectors from the diode and strip approximately 32 mm (1.25") of insulation from the cut ends of the wires (Figure 2). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6955 8. Twist the ends of the diode wires around the exposed wire on circuits 57 and 321 (Figure 3). 9. Solder the diode wires to circuits 57 and 321. Use rosin core mildly activated (RMA) solder. DO NOT USE ACID CORE SOLDER 10. Slip Dual Wall Heat Shrink Tubing (Motorcraft part # WT-5627-A) containing hot melt wax up the terminal ends of circuits 57 and 321 over the exposed wire. NOTE IT IS IMPORTANT TO USE HEAT SHRINK TUBING CONTAINING HOT MELT WAX OVER A SOLDERED CIRCUIT JOINT TO CREATE A WATERPROOF AND AIRTIGHT CONNECTION. MAKE SURE THAT THE TUBING COVERS ALL EXPOSED WIRES PLUS AT LEAST A HALF INCH AT BOTH ENDS (FIGURE 4). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 04-19-11 > Sep > 04 > A/C - Lack of Cooling/Restricted Air Flow From Vents > Page 6956 11. Heat the entire length of the heat shrink tubing until the hot melted wax appears from both ends of the tubing (Figure 5). 12. Reconnect connector C128 or C1033 (as applicable). 13. Reconnect the battery and test the circuit for correct A/C operation. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041911A Replace A/C 0.9 Hr. Clutch Relay And Install Diode (Includes Time To Monitor PIDS And Replace Low Pressure Switch If Necessary Does Not Include Time For Diagnosis Outside Of TSB Or Wiring Shorts) DEALER CODING CONDITION BASIC PART NO. CODE 14N089 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 6959 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications Compressor Clutch Cycling Switch Closes at: 276-324 kPa Opens at: 152-193 kPa Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6960 Refrigerant Pressure Sensor / Switch: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6961 Manual A/C Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6962 EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 6963 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 6966 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling 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. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - (SCP) communication. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 6967 Air Conditioning High Pressure 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Compressor Cut-Off/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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 6970 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6974 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6975 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6976 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6977 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6981 Refrigeration System Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6982 Service Gauge Port Values Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6983 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 after repairing the refrigerant system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations EATC System Electrical Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6987 Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6988 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6989 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6990 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Diagrams Vacuum Check Valve HVAC: Diagrams Vacuum Schematic - Manual A/C Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Diagrams > Page 6994 Vacuum Schematic - Electronic Automatic Temperature Control Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 6999 Vacuum Harness HVAC: Technician Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 7000 Vacuum Harness HVAC: Service and Repair Vacuum Pump Kit SPECIAL SERVICE 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 VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 7001 Vacuum Tester Kit Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations Control Components Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations > Page 7005 Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the relay module. 2. Disconnect the vacuum hose. 3. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat mounting points Safety belts, safety belt buckles and safety belt retractors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 7011 SRS wiring, wiring harnesses and connectors 7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 7012 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDE 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. ALL BELT ASSEMBLIES SHOULD BE INSTALLED NEW UNLESS 8 QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE CORRECTLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED. NEW SAFETY BELT ASSEMBLIES SHOULD BE INSTALLED IF EITHER DAMAGE OR INCORRECT OPERATION IS NOTED. NOTE: The driver and front passenger seat belt system (including belt and retractor assembly, buckles, and height adjusters) must be replaced if the vehicle is involved in a collision that results in deployment of the front air bags and safety belt pretensioners. 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). Carry out the Functional Test. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7018 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7019 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7020 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7021 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7022 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Driver Air Bag Module Bolts 12 Nm Passenger Air Bag Module Bolts 9 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 7028 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation Air Bag: Service and Repair Removal and Installation Module - Driver Air Bag 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. ^ 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 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7031 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 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Module - Passenger 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7032 ^ 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. ^ 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 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7033 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7034 ^ 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7035 Air Bag: Service and Repair Air Bag Disposal Procedures Deployed Air Bag 1. Dispose of the deployed air bag modules and safety belt pretensioners 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. Undeployed Air Bag - Inoperative WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: All inoperative air bag modules and safety belt pretensioners have been placed on the Mandatory Return List. All discolored or damaged air bag modules must be treated the same as any inoperative live air bag being returned. 1. Remove the inoperative component from the vehicle. 2. If installing a new driver air bag module: 1 For a new driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. 2 For a new passenger 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. Driver WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. 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 OR DEPLOYMENT DOOR 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7036 1. Remove the driver air bag from the vehicle. 2. Cut and strip the wires at the driver air bag electrical connector. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the stripped ends of the driver air bag module wires. 4. Place the air bag module on a flat surface in an open outdoor area with the trim cover facing upward. 5. Remain at least 6.1 meters (20 feet) away from the air bag module. 6. Deploy the air bag module by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching the deployed air bag. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Passenger WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. 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 OR DEPLOYMENT DOOR 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7037 1. Remove the passenger air bag from the vehicle. 2. Cut and strip the wires near the passenger air bag electrical connector. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the stripped ends of the passenger air bag module wires. 4. Place the air bag module on a flat surface in an open outdoor area with the deflector can facing downward. 5. Remain at least 6.1 meters (20 feet) away from the air bag module. 6. Deploy the air bag module by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching the deployed air bag. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7038 Air Bag: Service and Repair Weld Nut Repair "J" Nut 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. ^ 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 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 number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S1O1, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) 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 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. ^ 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 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 (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 7039 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 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. ^ 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 AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 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 VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7043 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7044 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7045 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 scan tool. 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7046 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. ^ 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 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 7047 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations Air Bag Sliding Contact: Locations The air bag sliding contact is mounted on the steering column, behind the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7051 Air Bag Sliding Contact: Description and Operation 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7052 Air Bag Sliding Contact: 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. ^ 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 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7053 5. Place the steering column in the full down tilt position, then remove the tilt wheel handle and shank. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7054 8. Remove the lower steering column shroud. 1 Remove the four screws. 2 Remove the lower steering column shroud. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7055 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7056 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7057 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7058 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. 8. Connect the transmission range indicator cable. 9. Tighten the aft steering column mounting nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7059 10. Tighten the forward steering column mounting nuts. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Locations > Page 7060 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. 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA00V050000 > Feb > 00 > Recall 00V050000: Airbag Crash Sensor Module Bolts Impact Sensor: Recalls Recall 00V050000: Airbag Crash Sensor Module Bolts Vehicle Description: Passenger vehicles. These vehicles may have been built with lower than the intended level of torque on the bolts that attach the airbag electronic crash sensor module to the vehicle. A loose module could result in a delayed air bag deployment in the event of a vehicle crash. Dealers will tighten the air bag electronic crash sensor attaching bolts. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA00V050000 > Feb > 00 > Recall 00V050000: Airbag Crash Sensor Module Bolts Impact Sensor: All Technical Service Bulletins Recall 00V050000: Airbag Crash Sensor Module Bolts Vehicle Description: Passenger vehicles. These vehicles may have been built with lower than the intended level of torque on the bolts that attach the airbag electronic crash sensor module to the vehicle. A loose module could result in a delayed air bag deployment in the event of a vehicle crash. Dealers will tighten the air bag electronic crash sensor attaching bolts. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 7074 Impact Sensor: Specifications Air Bag Sensor Bolts 12 Nm Crash Sensor Grounding Screw (N802455-S190) Weld Nut Repair Screw (8 mm) 12 Nm Grounding Screw (6 mm) (N806327-S190) 12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Crash Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Front Crash Sensor > Page 7077 Impact Sensor: Locations Right Primary Crash Sensor Right hand front of the vehicle, on the front of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7078 Impact Sensor: Description and Operation WARNING: THE AIR BAG ELECTRONIC 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 ARE~ OF THE ECS MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS contains two sensors which are integral to the ECS. The ECS is mounted on the RH A-pillar. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7079 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. ^ 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 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7080 ^ 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 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Conventional Malfunction Lamp / Indicator: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Conventional > Page 7085 Malfunction Lamp / Indicator: Description and Operation Electronic 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 VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7090 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7091 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7092 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 scan tool. 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7093 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. ^ 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 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 7094 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 7099 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7105 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7106 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7107 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7108 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7109 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Attaching Safety Seats With Tether Straps Child Seat Tether Attachment: Description and Operation Attaching Safety Seats With Tether Straps WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF EQUIPPED, SHOULDER BELT HEIGHT ADJUSTERS, IF EQUIPPED, CHILD SAFETY SEAT TETHER BRACKET ASSEMBLIES, IF EQUIPPED, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS NEW SAFETY BELT ASSEMBLIES 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. ^ EACH SEATING POSITION IN THE VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH CONSISTS OF ONE BUCKLE AND ONE TONGUE. THE SAFETY BELT ASSEMBLY IS DESIGNED TO BE USED AS A PAIR AND IS NOT TO BE USED ACROSS SEATING POSITIONS. Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Others manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Attaching Safety Seats With Tether Straps > Page 7115 Child Seat Tether Attachment: Description and Operation Child Safety Seat Tether Attachment WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF EQUIPPED, SHOULDER BELT HEIGHT ADJUSTERS, IF EQUIPPED, CHILD SAFETY SEAT TETHER BRACKET ASSEMBLIES, IF EQUIPPED, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS NEW SAFETY BELT ASSEMBLIES 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. ^ EACH SEATING POSITION IN THE VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH CONSISTS OF ONE BUCKLE AND ONE TONGUE. THE SAFETY BELT ASSEMBLY IS DESIGNED TO BE USED AS A PAIR AND IS NOT TO BE USED ACROSS SEATING POSITIONS. Child safety seat tether anchors have been provided at all three rear seating positions. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7124 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7125 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7126 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7127 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7128 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7129 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7130 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7131 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7132 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7133 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7134 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7135 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7136 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7137 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7138 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7143 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7144 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7145 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7146 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7147 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7148 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7149 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7150 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7151 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7152 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7153 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7154 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7155 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7156 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7157 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V157001 > Jun > 00 > Recall 00V157001: Service Stock Seat Belt Assemblies Safety 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V157002 > Jun > 00 > Recall 00V157002: Service Stock Seat Belt Assemblies Safety 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 05-3-10 > Feb > 05 > Restraints - Seat Belt Stop Button Service Safety Belt: All Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7175 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7176 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7177 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7178 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7179 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7180 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7181 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7182 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7183 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7184 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7185 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7186 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7187 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7188 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7189 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7194 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7195 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7196 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7197 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7198 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7199 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7200 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7201 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7202 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7203 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7204 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7205 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7206 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7207 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7208 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > NHTSA00V157001 > Jun > 00 > Recall 00V157001: Service Stock Seat Belt Assemblies Safety 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Safety Belt: > NHTSA00V157002 > Jun > 00 > Recall 00V157002: Service Stock Seat Belt Assemblies Safety 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Safety Belt: > 05-3-10 > Feb > 05 > Restraints - Seat Belt Stop Button Service Safety Belt: All Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Page 7222 Safety Belt: Specifications Front Safety Belt to Floor Pan Bolt 40 Nm Rear Safety Belt to Floor Pan Bolt 48 Nm Front Center Safety Belt Buckle to Seat Nut 40 Nm D-Ring Nut 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Technical Service Bulletins > Page 7223 Safety Belt: Description and Operation WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF EQUIPPED, SHOULDER BELT HEIGHT ADJUSTERS, IF EQUIPPED, CHILD SAFETY SEAT TETHER BRACKET ASSEMBLIES, IF EQUIPPED, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS NEW SAFETY BELT ASSEMBLIES 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. ^ EACH SEATING POSITION IN THE VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH CONSISTS OF ONE BUCKLE AND ONE TONGUE. THE SAFETY BELT ASSEMBLY IS DESIGNED TO BE USED AS A PAIR AND IS NOT TO BE USED ACROSS SEATING POSITIONS. Safety Belt, Lap/Shoulder 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. Safety Belt, Lap/Shoulder-Dual Locking Mode 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Removal and Installation Safety Belt: Service and Repair Removal and Installation REMOVAL 1. Remove the driver seat safety belt buckle. 2. Remove the front seat center safety belt. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Removal and Installation > Page 7226 Safety Belt: Service and Repair General Procedures Safety Belt Maintenance WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDE 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. ALL BELT ASSEMBLIES SHOULD BE INSTALLED NEW UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE CORRECTLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED. NEW SAFETY BELT ASSEMBLIES SHOULD BE 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) using the appropriate instructions. Carry out the Functional Test Procedure. See: Testing and Inspection/Component Tests and General Diagnostics/Functional Tests Safety Belt Cleaning 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. Safety 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 anchor bolts must be hand-started and then tightened to the correct torque specifications. 2. Drill out the internal threads in the safety belt anchor plate with a 27/64 inch drill bit. 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. Install a new bolt, hand-tighten and then tighten to correct torque specifications. NOTE: New parts are to be used in place of the original parts; refer to the Parts Replacement Chart-Safety Belt with Damaged Weld Nut Anchor Plate Threads. See: Parts Replacement Chart Safety Belt Tongue Rotated on Belt 1. Grasp the belt tongue and pull the belt webbing down to form a loop through the 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 slot in the belt tongue. 4. Pull the excess belt webbing through the slot. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Removal and Installation > Page 7227 5. The safety belt tongue should face inward when completed. Parts Replacement Chart-Safety Belt with Damaged Weld Nut Anchor Plate Threads Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Specifications Safety Belt Buckle: Specifications Rear Safety Belt Buckle/Buckle Combination to Floor Pan Bolt 48 Nm Rear Safety Belt Buckle/Belt Combination to Floor Pan Bolt 48 Nm Front Safety Belt Buckle to Seat Nut 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Specifications > Page 7231 Safety Belt Buckle: Description and Operation WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF EQUIPPED, SHOULDER BELT HEIGHT ADJUSTERS, IF EQUIPPED, CHILD SAFETY SEAT TETHER BRACKET ASSEMBLIES, IF EQUIPPED, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS NEW SAFETY BELT ASSEMBLIES 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. ^ EACH SEATING POSITION IN THE VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH CONSISTS OF ONE BUCKLE AND ONE TONGUE. THE SAFETY BELT ASSEMBLY IS DESIGNED TO BE USED AS A PAIR AND IS NOT TO BE USED ACROSS SEATING POSITIONS. Safety Belt, Buckle End-Front 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - Front Safety Belt Buckle: Service and Repair Safety Belt Buckle - Front REMOVAL Driver and Front Passenger Seat 1. Remove the front seat. Driver Side Only 2. Disconnect the connector. Driver and Front Passenger Seat 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 proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - Front > Page 7234 Safety Belt Buckle: Service and Repair Safety Belt Buckle - Rear 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 proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Height Adjuster Bolt 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation FRONT HEIGHT ADJUSTER 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 proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 7243 Seat Belt Height Adjuster: Service and Repair General Procedures D - Ring Installation Kit Special Service Tool(s) 1. Remove the shoulder safety belt height adjuster. 2. Use the half-inch drill with integral stop provided in the D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in the D-Ring Installation 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 (#N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 7244 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped; refer to Height Adjuster-Front. If the bolts are stripped, install a new height adjuster. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder Seat Belt Reminder Lamp: Description and Operation Belt Minder Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder > Page 7252 Seat Belt Reminder Lamp: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder > Page 7253 Seat Belt Reminder Lamp: Description and Operation Electronic The safety belt warning indicator is directly hardwired to the Lighting Control Module (LCM). The LCM controls the safety belt warning indicator depending on the signal it receives from the safety belt buckle switch. The safety belt warning indicator illuminates when the safety belt is not buckled, closing the safety belt buckle switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder > Page 7254 Seat Belt Reminder Lamp: Description and Operation Warning Devices NOTE: The belt minder feature is configurable. If configuring using a scan tool, refer to Module Communications Network (Information Bus). To configure without using a scan tool, refer to Belt Minder Deactivation/Activation. The belt minder feature supplements the current safety belt warning function. The belt minder feature is enabled after the current safety belt warning is complete. If the driver safety belt is not buckled approximately five seconds after the safety belt warning light has turned off, the belt minder reminds the driver that their safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. While activated, the belt minder alternates the chime and indicator from on for 6 seconds to off for 30 seconds. The belt minder reminder stops when: - the driver safety belt is buckled. - the ignition is turned to OFF or ACC. - five minutes have elapsed since belt minder has started. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 7255 Seat Belt Reminder Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7264 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7265 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7266 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7267 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7268 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7269 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7270 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7271 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7272 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7273 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7274 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7275 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7276 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7277 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7278 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7283 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7284 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7285 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7286 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7287 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7288 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7289 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7290 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7291 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7292 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7293 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7294 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7295 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7296 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7297 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V083000 > Mar > 00 > Recall 00V083000: Seat Belt Retractor Bolts Loose Seat Belt Retractor: Recalls Recall 00V083000: Seat Belt Retractor Bolts Loose Vehicle Description: Passenger vehicles. These vehicles may have been built with the left rear seat belt retractor attaching bolts incorrectly tightened. In the event of a crash, the vehicle occupant may not be properly restrained, increasing the risk of personal injury. Dealers will tighten the retractor mounting bolts to the specified torque. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 7307 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 7313 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7318 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7319 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7320 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7321 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7322 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7323 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7324 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7325 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7326 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7327 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7328 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7329 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7330 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7331 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7332 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7337 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7338 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7339 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7340 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7341 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7342 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7343 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7344 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7345 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7346 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7347 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7348 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7349 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7350 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt 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 7351 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > NHTSA00V083000 > Mar > 00 > Recall 00V083000: Seat Belt Retractor Bolts Loose Seat Belt Retractor: All Technical Service Bulletins Recall 00V083000: Seat Belt Retractor Bolts Loose Vehicle Description: Passenger vehicles. These vehicles may have been built with the left rear seat belt retractor attaching bolts incorrectly tightened. In the event of a crash, the vehicle occupant may not be properly restrained, increasing the risk of personal injury. Dealers will tighten the retractor mounting bolts to the specified torque. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 7361 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7367 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7368 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7369 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7370 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7371 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7372 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7373 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7374 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7375 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7376 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7377 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7378 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7379 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7380 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 7381 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7386 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7387 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7388 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7389 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7390 Table 1 * # 150 * Crown Victoria/Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7391 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7392 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7393 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7394 ^ 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7395 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7396 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7397 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7398 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7399 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 7400 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > NHTSA00V083000 > Mar > 00 > Recall 00V083000: Seat Belt Retractor Bolts Loose Seat Belt Retractor: All Technical Service Bulletins Recall 00V083000: Seat Belt Retractor Bolts Loose Vehicle Description: Passenger vehicles. These vehicles may have been built with the left rear seat belt retractor attaching bolts incorrectly tightened. In the event of a crash, the vehicle occupant may not be properly restrained, increasing the risk of personal injury. Dealers will tighten the retractor mounting bolts to the specified torque. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 7405 Seat Belt Retractor: Specifications Front Retractor Bolt 40 Nm Rear Retractor Bolt 40 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor Seat Belt Retractor: Service and Repair Front Safety Belt Retractor 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7408 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 VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7409 9. Remove the screw. 10. Remove the retractor. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7410 1. To install, reverse the removal procedure. 2. Check the restraint system for proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 7411 Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor 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 proper operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 7416 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Timer: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 7421 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls for Impact Sensor: > NHTSA00V050000 > Feb > 00 > Recall 00V050000: Airbag Crash Sensor Module Bolts Impact Sensor: Recalls Recall 00V050000: Airbag Crash Sensor Module Bolts Vehicle Description: Passenger vehicles. These vehicles may have been built with lower than the intended level of torque on the bolts that attach the airbag electronic crash sensor module to the vehicle. A loose module could result in a delayed air bag deployment in the event of a vehicle crash. Dealers will tighten the air bag electronic crash sensor attaching bolts. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA00V050000 > Feb > 00 > Recall 00V050000: Airbag Crash Sensor Module Bolts Impact Sensor: All Technical Service Bulletins Recall 00V050000: Airbag Crash Sensor Module Bolts Vehicle Description: Passenger vehicles. These vehicles may have been built with lower than the intended level of torque on the bolts that attach the airbag electronic crash sensor module to the vehicle. A loose module could result in a delayed air bag deployment in the event of a vehicle crash. Dealers will tighten the air bag electronic crash sensor attaching bolts. All vehicles are either at the St. Thomas Assembly Plant or at dealerships. No vehicles have been delivered to customers. No owner notification will be required. 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Page 7436 Impact Sensor: Specifications Air Bag Sensor Bolts 12 Nm Crash Sensor Grounding Screw (N802455-S190) Weld Nut Repair Screw (8 mm) 12 Nm Grounding Screw (6 mm) (N806327-S190) 12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Crash Sensor Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Front Crash Sensor > Page 7439 Impact Sensor: Locations Right Primary Crash Sensor Right hand front of the vehicle, on the front of the upper radiator support. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7440 Impact Sensor: Description and Operation WARNING: THE AIR BAG ELECTRONIC 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 ARE~ OF THE ECS MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS contains two sensors which are integral to the ECS. The ECS is mounted on the RH A-pillar. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7441 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. ^ 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 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7442 ^ 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 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. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable Antenna Cable: Service and Repair Antenna Lead In, Font Cable REMOVAL 1. Remove the audio unit; refer to Radio, Stereo, and Compact Disc. 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7451 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7452 Antenna Cable: Service and Repair Antenna Lead In, Rear Cable 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7453 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. 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7454 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7455 5. Install the A-pillar lower trim panel. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7456 9. Install the scuff plates 10. Install the roof side rear trim panels. 11. Install the package tray trim panel. 12. 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 the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead In, Font Cable > Page 7457 Antenna Cable: Service and Repair Isolator Module to FM Antenna Cable 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Control Module > Page 7463 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Control Module > Page 7466 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7467 Alarm Module: Service Precautions CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to a scan tool. This information needs to be downloaded in to the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network (Information Bus). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7468 Alarm Module: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Antitheft and Alarm Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7469 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to a scan tool. This information needs to be downloaded in to the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7470 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 scan tool into the new module. For additional information; refer to Module Communications Network (Information Bus). 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 7474 Alarm System Transponder: Service Precautions CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 7475 Alarm System Transponder: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Antitheft and Alarm Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 7476 Alarm System Transponder: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 7477 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 7478 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 7483 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the driver door panel. 3. Position weather shield aside. 4. Remove the keyless entry keypad. 1 Remove the Clip and remove the keyless entry keypad. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions Keyless Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions > Page 7487 Keyless Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions > Page 7488 Keyless Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions > Page 7489 Keyless Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Programming Transmitter Keyless Entry Transmitter: Service and Repair Programming Transmitter 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. NOTE: Keyless entry remote transmitters can also be programmed using a scan tool and the Ford Service Function (FSF) card. 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Programming Transmitter > Page 7494 Keyless Entry Transmitter: Service and Repair Autolock and Horn Chirp Programming 1. Turn the ignition switch to RUN. NOTE: This procedure must be completed within 30 seconds. 2. Press the UNLOCK button three times. 3. Turn the ignition switch to OFF. 4. Press the UNLOCK button three times. 5. Turn the ignition switch to RUN. The doors Will lock and unlock to confirm entry into program mode. 6. Press the UNLOCK button once to toggle the Autolock feature on or off; or twice to toggle the Horn Chirp function on or off. The horn will chirp to confirm toggling of the Autolock feature. 7. Exit program mode by turning the ignition to OFF, START, or wait 7.5 seconds. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 7498 Driver/Vehicle Information Display: Description and Operation The message center information is integrated in the electronic instrument cluster. The instrument cluster receives the needed message center signals from the Vehicle Speed Sensor (VSS), fuel level sensor (part of the fuel pump module), and the Powertrain Control Module (PCM). The message center information can be toggled by pressing the appropriate message center switch. The message center display proves out when the instrument cluster prove-out, when the ignition switch is turned to the ON position. The message center then resumes the mode of operation last used. The message center displays are as follows: - average fuel economy (AVG ECON) - average speed (AVG SPEED) - distance to empty (DIST TO EMPTY) - instantaneous fuel economy (INST ECON) - trip distance A (TRIP A) - trip distance B (TRIP B) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 7499 Driver/Vehicle Information Display: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center switch Driver/Vehicle Information Display: Service and Repair Message Center switch REMOVAL 1. Remove the instrument cluster finish panel. Refer to Dash Board. 2. Remove the message center switch. 1 Remove the screws. 2 Remove the message center switch. - Install new illumination bulbs as necessary. NOTE: The illumination bulbs are replaceable. INSTALLATION 1. To install, reverse the removal procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 7502 73III Automotive Meter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service Precautions Garage Door Opener Transmitter: Service Precautions 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. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service Precautions > Page 7506 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7509 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7510 Garage Door Opener Transmitter: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 7511 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 25-51 mm (1-2 in) 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. Training a Garage Door Opener Equipped With "Roiling 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 7512 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module Multifunction Electronic Control Modules: Locations Air Suspension Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module > Page 7517 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module > Page 7518 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7535 Multifunction Electronic Control Modules: Connector Views Lighting Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7536 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7537 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7538 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7539 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 7541 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ 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. For additional information, refer to Module Communications Network (Information Bus). ^ 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. For additional information, refer to Module Communications Network (Information Bus) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 7542 Multifunction Electronic Control Modules: 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. 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). 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. The 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 input signals from various switches, sensors, and external modules. LCM subsystem functions 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 (DDM) via SCP for illuminated entry Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 7543 Multifunction Electronic Control Modules: Testing and Inspection For air suspension concerns, refer to Electronic Level Control. See: Steering and Suspension/Suspension For Electronic Variable Orifice (EVO) steering concerns, refer to Steering. See: Steering and Suspension/Steering For warning chime concerns, refer to Instrument Panel, Gauges and Warning Indicators. See: Instrument Panel, Gauges and Warning Indicators For interior lighting concerns, refer to Courtesy Lamp. See: Lighting and Horns/Courtesy Lamp/Testing and Inspection For exterior lighting concerns, refer to the following sub-systems in Lighting and Horns: Backup Lamp. See: Lighting and Horns/Reversing Lamp/Testing and Inspection Brake Lamp. See: Lighting and Horns/Brake Lamp/Testing and Inspection Daytime Running Lamp. See: Lighting and Horns/Daytime Running Lamp/Testing and Inspection Headlamp/Autolamp. See: Lighting and Horns/Headlamp/Testing and Inspection Parking Lamp/Tail Lamp/License Lamp. See: Lighting and Horns/Parking Lamp/Testing and Inspection Public Safety Police Package Lighting. See: Lighting and Horns/Testing and Inspection Turn Signals/Hazard Lamps. See: Lighting and Horns/Turn Signals/Testing and Inspection For power window or defroster concerns, refer to Windows. See: Windows and Glass/Testing and Inspection For power lock and/or keyless entry concerns, refer to Keyless Entry. See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7546 Multifunction Electronic Control Modules: Service and Repair Driver Door Module(DDM) 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. For additional information, refer to Module Communications Network (Information Bus). 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. For additional information, refer to Module Communications Network (Information Bus) 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7547 Multifunction Electronic Control Modules: Service and Repair Lighting Control (LCM) Module 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 into the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ 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 screws. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7548 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 New Generation STAR (NGS) Tester into the new module. For additional information; refer to Module Communications Network (Information Bus). 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications CD Changer: Specifications Compact Disc Changer Bolts 8 Nm Compact Disc Changer Nuts 8 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications > Page 7557 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications > Page 7558 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 VIN W (2000)) 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 VIN W (2000)) 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 7568 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 VIN W (2000)) 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 7569 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 VIN W (2000)) 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 7570 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 VIN W (2000)) 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 7571 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 VIN W (2000)) 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 7572 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 VIN W (2000)) 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 7573 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 7574 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 7580 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 VIN W (2000)) 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 7581 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 VIN W (2000)) 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 7582 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 VIN W (2000)) 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 7583 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 VIN W (2000)) 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 7584 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 VIN W (2000)) 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 7585 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 7586 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 7587 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 7596 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 VIN W (2000)) 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 7597 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 VIN W (2000)) 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 7598 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 VIN W (2000)) 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 7599 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 VIN W (2000)) 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 7600 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 VIN W (2000)) 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 7601 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 7602 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 7608 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 VIN W (2000)) 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 7609 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 VIN W (2000)) 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 7610 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 VIN W (2000)) 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 7611 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 VIN W (2000)) 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 7612 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 VIN W (2000)) 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 7613 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 7614 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7615 Speaker: Specifications Radio Speakers Screws 2 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7616 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) 18971 ^ radio speaker (front base and premium) 18971 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers Speaker: Service and Repair Door Mounted Speakers 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers > Page 7619 Speaker: Service and Repair Package Tray Speakers 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Control Module > Page 7625 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Control Module > Page 7628 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7629 Alarm Module: Service Precautions CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to a scan tool. This information needs to be downloaded in to the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network (Information Bus). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7630 Alarm Module: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Antitheft and Alarm Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7631 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to a scan tool. This information needs to be downloaded in to the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7632 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 scan tool into the new module. For additional information; refer to Module Communications Network (Information Bus). 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module Multifunction Electronic Control Modules: Locations Air Suspension Module Behind right hand side of the Instrument Panel (I/P), above the glove box. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module > Page 7637 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations > Air Suspension Module > Page 7638 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7641 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7642 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7643 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7644 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7645 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7646 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7647 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7648 Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7649 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7650 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7651 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7652 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Multifunction Electronic Control Modules: Connector Views Lighting Control Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 58-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Diagram 58-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 Diagram 58-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 7661 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ 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. For additional information, refer to Module Communications Network (Information Bus). ^ 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. For additional information, refer to Module Communications Network (Information Bus) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 7662 Multifunction Electronic Control Modules: 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. 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). 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. The 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 input signals from various switches, sensors, and external modules. LCM subsystem functions 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 (DDM) via SCP for illuminated entry Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 7663 Multifunction Electronic Control Modules: Testing and Inspection For air suspension concerns, refer to Electronic Level Control. See: Steering and Suspension/Suspension For Electronic Variable Orifice (EVO) steering concerns, refer to Steering. See: Steering and Suspension/Steering For warning chime concerns, refer to Instrument Panel, Gauges and Warning Indicators. See: Instrument Panel, Gauges and Warning Indicators For interior lighting concerns, refer to Courtesy Lamp. See: Lighting and Horns/Courtesy Lamp/Testing and Inspection For exterior lighting concerns, refer to the following sub-systems in Lighting and Horns: Backup Lamp. See: Lighting and Horns/Reversing Lamp/Testing and Inspection Brake Lamp. See: Lighting and Horns/Brake Lamp/Testing and Inspection Daytime Running Lamp. See: Lighting and Horns/Daytime Running Lamp/Testing and Inspection Headlamp/Autolamp. See: Lighting and Horns/Headlamp/Testing and Inspection Parking Lamp/Tail Lamp/License Lamp. See: Lighting and Horns/Parking Lamp/Testing and Inspection Public Safety Police Package Lighting. See: Lighting and Horns/Testing and Inspection Turn Signals/Hazard Lamps. See: Lighting and Horns/Turn Signals/Testing and Inspection For power window or defroster concerns, refer to Windows. See: Windows and Glass/Testing and Inspection For power lock and/or keyless entry concerns, refer to Keyless Entry. See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module Multifunction Electronic Control Modules: 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7666 Multifunction Electronic Control Modules: Service and Repair Driver Door Module(DDM) 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. For additional information, refer to Module Communications Network (Information Bus). 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. For additional information, refer to Module Communications Network (Information Bus) 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7667 Multifunction Electronic Control Modules: Service and Repair Lighting Control (LCM) Module 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 into the new module once installed. For additional information; refer to Module Communications Network (Information Bus). ^ 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 screws. 2 Release the locking tab. 3 Position the LCM aside. 4. Remove the LCM. 1 Disconnect the electrical connectors. 2 Remove the LCM. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Air Suspension Module > Page 7668 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 New Generation STAR (NGS) Tester into the new module. For additional information; refer to Module Communications Network (Information Bus). 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 VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions Keyless Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 7672 Keyless Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 7673 Keyless Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service Precautions > Page 7674 Keyless Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair BUMPER COVER-FRONT Removal All Vehicles 1. Remove the bolts. 2. Remove the bolt from each side. 3. Remove the screws from each side. 4. Remove the cornering lamp assemblies. Grand Marquis Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 7681 5. Remove the bolt from each side. Crown Victoria 6. Remove the screw from each side. All Vehicles 7. Remove the bolt from each side. 8. Release the four tabs to remove the front bumper cover (l715957). Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 7682 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Bumper Isolator - Front Front Bumper Reinforcement: Service and Repair Bumper Isolator - Front BUMPER-FRONT ISOLATOR Removal 1. Remove the front bumper cover (17D957). 2. Remove the front bumper (17757). 3. Remove the bolt. 4. Remove the isolator (17754). 5. Remove the nuts. Installation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Bumper Isolator - Front > Page 7687 1. To install, Reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Bumper Isolator - Front > Page 7688 Front Bumper Reinforcement: Service and Repair Front Bumper BUMPER-FRONT Removal 1. Remove the front bumper cover (17D957). 2. Remove the pin-type retainers. 3. Remove the nuts from each side. Installation 1. To install, reverse file removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair BUMPER COVER-REAR Removal 1. Remove the bolts. 2. Remove the three pin-type retainers on each side. 3. Remove the screws on each side. 4. Remove the luggage compartment trim. 5. Remove the nuts from each side. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 7693 6. Remove the nuts from each side. Installation 1. To install, Reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Bumper-Rear Isolator Rear Bumper Reinforcement: Service and Repair Bumper-Rear Isolator BUMPER-REAR ISOLATOR Removal 1. Remove the rear bumper cover (17K835). 2. Remove the rear bumper (17906). 3. Remove the bolt. 4. Remove the isolator (17787). Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Bumper-Rear Isolator > Page 7698 Rear Bumper Reinforcement: Service and Repair Rear Bumper BUMPER-REAR Removal 1. Remove the rear bumper cover (17K835). 2. Remove the nuts from each side. 3. Remove the rear bumper (17906). Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 02-7-4 > Apr > 02 > Door Hinge Squeak/Creak Noise Front Door Hinge: Customer Interest Door Hinge - Squeak/Creak Noise Article No. 02-7-4 04/15/02 NOISE - SQUEAK/CREAK NOISE COMING FROM DOOR HINGE AREA FORD: 2000-2002 CROWN VICTORIA MERCURY: 2000-2002 GRAND MARQUIS ISSUE Some vehicles may exhibit a squeak/creak noise coming from the left front or right front door hinge area. This may be caused by the door reinforcement tapping plate edges rubbing against the door reinforcement (Figure 1). This tapping plate may contact the door reinforcement bridge, located on the inside door, across from the hinge. ACTION Verify condition. Apply Ford Long Life Lubricating Grease, part number F5AZ-19G209-AA) on the hinges in the area specified. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow these steps to correct a squeak caused by the tapping plate: 1. Open the door. 2. Apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the hinges to the outside surface while the door is open. 3. Open and close the door several times. If the squeak/creak is still present: 4. Remove the door inner panel. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 5. Remove the speaker. 6. Reach inside and apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the top and bottom inside hinge reinforcements (sheet metal and tapping plate). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 02-7-4 > Apr > 02 > Door Hinge Squeak/Creak Noise > Page 7714 7. Re-install the door panel and speaker. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 8. Verify the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Pr6visions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020704A Lubricate One Front Door, 0.2 Hr. Check Operation 020704B Lubricate Two Front Doors, 0.3 Hr. Check Operation 020704C Lubricate One Front Door, 0.5 Hr. Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinge 020704D Lubricate Both Front 0.8 Hr. Doors, Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinges DEALER CODING CONDITION BASIC PART NO. CODE 5422810 91 OASIS CODES: 112000, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 02-7-4 > Apr > 02 > Door Hinge - Squeak/Creak Noise Front Door Hinge: All Technical Service Bulletins Door Hinge - Squeak/Creak Noise Article No. 02-7-4 04/15/02 NOISE - SQUEAK/CREAK NOISE COMING FROM DOOR HINGE AREA FORD: 2000-2002 CROWN VICTORIA MERCURY: 2000-2002 GRAND MARQUIS ISSUE Some vehicles may exhibit a squeak/creak noise coming from the left front or right front door hinge area. This may be caused by the door reinforcement tapping plate edges rubbing against the door reinforcement (Figure 1). This tapping plate may contact the door reinforcement bridge, located on the inside door, across from the hinge. ACTION Verify condition. Apply Ford Long Life Lubricating Grease, part number F5AZ-19G209-AA) on the hinges in the area specified. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow these steps to correct a squeak caused by the tapping plate: 1. Open the door. 2. Apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the hinges to the outside surface while the door is open. 3. Open and close the door several times. If the squeak/creak is still present: 4. Remove the door inner panel. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 5. Remove the speaker. 6. Reach inside and apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the top and bottom inside hinge reinforcements (sheet metal and tapping plate). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 02-7-4 > Apr > 02 > Door Hinge - Squeak/Creak Noise > Page 7720 7. Re-install the door panel and speaker. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 8. Verify the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Pr6visions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020704A Lubricate One Front Door, 0.2 Hr. Check Operation 020704B Lubricate Two Front Doors, 0.3 Hr. Check Operation 020704C Lubricate One Front Door, 0.5 Hr. Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinge 020704D Lubricate Both Front 0.8 Hr. Doors, Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinges DEALER CODING CONDITION BASIC PART NO. CODE 5422810 91 OASIS CODES: 112000, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7721 Front Door Hinge: By Symptom Technical Service Bulletin # 02-7-4 Date: 020415 Door Hinge - Squeak/Creak Noise Article No. 02-7-4 04/15/02 NOISE - SQUEAK/CREAK NOISE COMING FROM DOOR HINGE AREA FORD: 2000-2002 CROWN VICTORIA MERCURY: 2000-2002 GRAND MARQUIS ISSUE Some vehicles may exhibit a squeak/creak noise coming from the left front or right front door hinge area. This may be caused by the door reinforcement tapping plate edges rubbing against the door reinforcement (Figure 1). This tapping plate may contact the door reinforcement bridge, located on the inside door, across from the hinge. ACTION Verify condition. Apply Ford Long Life Lubricating Grease, part number F5AZ-19G209-AA) on the hinges in the area specified. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow these steps to correct a squeak caused by the tapping plate: 1. Open the door. 2. Apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the hinges to the outside surface while the door is open. 3. Open and close the door several times. If the squeak/creak is still present: 4. Remove the door inner panel. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 5. Remove the speaker. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7722 6. Reach inside and apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the top and bottom inside hinge reinforcements (sheet metal and tapping plate). 7. Re-install the door panel and speaker. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 8. Verify the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Pr6visions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020704A Lubricate One Front Door, 0.2 Hr. Check Operation 020704B Lubricate Two Front Doors, 0.3 Hr. Check Operation 020704C Lubricate One Front Door, 0.5 Hr. Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinge 020704D Lubricate Both Front 0.8 Hr. Doors, Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinges DEALER CODING CONDITION BASIC PART NO. CODE 5422810 91 OASIS CODES: 112000, 702000, 702100 Technical Service Bulletin # 02-7-4 Date: 020415 Door Hinge - Squeak/Creak Noise Article No. 02-7-4 04/15/02 NOISE - SQUEAK/CREAK NOISE COMING FROM DOOR HINGE AREA FORD: 2000-2002 CROWN VICTORIA MERCURY: 2000-2002 GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7723 ISSUE Some vehicles may exhibit a squeak/creak noise coming from the left front or right front door hinge area. This may be caused by the door reinforcement tapping plate edges rubbing against the door reinforcement (Figure 1). This tapping plate may contact the door reinforcement bridge, located on the inside door, across from the hinge. ACTION Verify condition. Apply Ford Long Life Lubricating Grease, part number F5AZ-19G209-AA) on the hinges in the area specified. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow these steps to correct a squeak caused by the tapping plate: 1. Open the door. 2. Apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the hinges to the outside surface while the door is open. 3. Open and close the door several times. If the squeak/creak is still present: 4. Remove the door inner panel. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 5. Remove the speaker. 6. Reach inside and apply Ford Long Life Lubricating Grease (F5AZ-19G209-AA) on the top and bottom inside hinge reinforcements (sheet metal and tapping plate). 7. Re-install the door panel and speaker. Refer to Section 501-05 of the Crown Victoria/Grand Marquis Work Shop Manual. 8. Verify the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Pr6visions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7724 020704A Lubricate One Front Door, 0.2 Hr. Check Operation 020704B Lubricate Two Front Doors, 0.3 Hr. Check Operation 020704C Lubricate One Front Door, 0.5 Hr. Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinge 020704D Lubricate Both Front 0.8 Hr. Doors, Check Operation, Remove Door Trim Panel And Lubricate Inner Door Hinges DEALER CODING CONDITION BASIC PART NO. CODE 5422810 91 OASIS CODES: 112000, 702000, 702100 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications Front Door Latch: Specifications Door Latch Screws 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 7728 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 7729 7. Disconnect the electrical connectors. 8. Disconnect the electrical 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 7730 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair TRIM PANEL-FRONT DOOR Removal 1. Remove the window regulator switch plate (14524). 2. Disconnect the connectors. 3. Remove the screw covers. 4. NOTE: Use care not to damage the trim panel when removing the screws. Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 7734 5. Remove the screws. 6. Remove the front door trim panel (23942). 7. Disconnect the connector. Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments Front Door Window Glass: Adjustments 1. Remove the front door trim panel. 2. Partially lower the front door window glass. 3. Loosen the top regulator nuts. 4. Fully raise the door window glass. 5. Tighten the nuts. 6. Cycle the window regulator fully to verify normal operation. 7. Install the front door trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments > Page 7738 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 Remove the pull strap handle. 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments > Page 7739 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 Nm(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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications Front Door Window Motor: Specifications No Load................................................................................................................................................ ....................................5 amperes or less at 12.8 volts Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 7743 Front Door Window Motor: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 7744 Front Door Window Motor: Service and Repair 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. For additional information, refer to Battery. 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 7745 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 VIN W (2000)) 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 Remove the pull strap handle. 3. Remove the front door window glass. For additional information, refer to Window Glass - Front Door. 4. Disconnect the connector. 5. Remove the rivets. 6. Remove the Torx(R) screws. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 7749 7. Remove the nuts. 8. Remove the regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications Rear Door Latch: Specifications Door Latch Screws 6 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 7758 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 7759 7. Remove the clip. 8. Disconnect the connectors. 9. Disconnect the connector. 10. Remove the rivet. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 7760 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair TRIM PANEL-REAR DOOR Removal 1. NOTE: Use care not to damage the trim panel when removing the screws. Remove the window regulator control switch bezel. 2. Remove the screws and the regulator control switch. 3. Remove the screw covers. 4. Remove the screws. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 7764 5. Remove the interior door handle cup (22896). 6. Remove the screws. 7. Remove the rear door trim panel (27406). Installation 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 7768 7. Remove the rear door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications Rear Door Window Motor: Specifications No Load................................................................................................................................................ ....................................5 amperes or less at 12.8 volts Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 7772 Rear Door Window Motor: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 7773 Rear Door Window Motor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 7774 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair 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. For additional information, refer to Window Glass - Rear Door. 5. Disconnect the connector. 6. Remove the rivets. 7. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 7778 8. Remove the rear door window regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Description and Operation Power Trunk / Liftgate Lock Switch: Description and Operation Refer to Keyless Entry. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Description and Operation Trunk / Liftgate Latch: Description and Operation The luggage compartment lid latch is equipped with a mechanical interior release handle. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 7796 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 7797 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 VIN W (2000)) 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 7798 ^ 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 VIN W (2000)) 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 7799 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 VIN W (2000)) 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 7800 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 7801 Trunk / Liftgate Lock Cylinder: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 7802 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Spring > Component Information > Adjustments Trunk / Liftgate Spring: Adjustments TORSION BAR LOADING WARNING: Safety glasses must be worn when performing this operation. 1. NOTE: The luggage compartment door tension should be decreased if the luggage compartment door opens with more force than desired. The luggage compartment door tension should be increased if the luggage compartment door opens with less force than desired. Open and support the luggage compartment door in the full-open position. 2. WARNING: Use care when adjusting the luggage compartment door/tailgate hinge torsion bar (44891). It is under tension and could spring out of control if it is not handled properly. Move the luggage compartment door end of the luggage compartment door/tailgate hinge torsion bar to another position. 3. Check the adjustment. 4. WARNING: Use care when adjusting the luggage compartment door/tailgate hinge torsion bar. It is under tension and could spring out of control if it is not handled properly. Move the luggage compartment door end of the luggage compartment door/tailgate hinge torsion bar to another position. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > System Information > Service and Repair Exterior Moulding / Trim: Service and Repair MOULDING-EXTERIOR Removal NOTE: Before removing the exterior mouldings, determine the type of retainer used and whether the respective door trim panel, quarter trim panel or luggage compartment trim panel must first be removed to provide access. 1. Remove the rear roof side trim panel. 2. Remove the roof side moulding. Installation 1. Follow the removal procedure in reverse order. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Fender > Component Information > Specifications Fender: Specifications Front Fender Splash Sheild Bolts 9-14 Nm Front Fender Splash Shield Locator Bolt 17 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation FRAME AND BODY MOUNTING Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts and drivetrain operation. Window glass cracks, door and window opening concerns, and air or water leaks at the doors are often caused by improperly tightened bolts and body misalignment. Every structural member and outer panel is designed to offer the maximum protection in the event of a collision. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7822 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7823 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7824 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7825 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7826 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 VIN W (2000)) 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 VIN W (2000)) 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 7835 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 VIN W (2000)) 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 VIN W (2000)) 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 7841 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 7844 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 7845 Headliner: Removal and Replacement HEADLINER Removal 1. Remove the front seats. 2. Remove the front door weatherstrips. 3. Remove the windshield side garnish mouldings (03512). 4. Disconnect the connector from the RH windshield pillar. 5. Remove the interior sun visors. 6. Remove the upper trim panel (24396). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 7846 7. Remove the passenger assist handles (31406). 8. Remove the upper trim panels (24396). 9. Remove the pin-type retainers. 10. NOTE: Pull down sides of headliner above the door openings to expose adhesive beads. Using a hot knife or wide-blade putty knife, cut adhesive beads lengthwise across the headliner. 11. NOTE: A new headliner must be installed if the headliner is folded in half for removal. Remove the headliner through the front door opening. 12. Clean any remaining adhesive from the roof sheet metal. Installation 1. NOTE: A new headliner will need to be installed if it is folded during removal or installation. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Procedures Rear Shelf: Procedures 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Procedures > Page 7851 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Procedures > Page 7852 Rear Shelf: Removal and Replacement TRIM PANEL-PACKAGE TRAY 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 (52018). 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Procedures > Page 7853 8. Remove the pin-type retainers. 9. Remove the package tray trim panel (46668). Installation 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7858 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. Upper Quarter Trim Panel REMOVAL 1. Remove the rear seat cushion. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7859 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7860 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7861 Trim Panel: Removal and Replacement Trim Panel-Upper B-Pillar TRIM PANEL-UPPER B-PILLAR Removal 1. Remove the front door scuff plate (13208). 2. Remove the rear door scuff plate (13228). 3. Pull back the front and rear door weatherstrips to clear the trim panels. 4. Remove the center body pillar lower finish panel (243A52). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7862 5. Remove the center D-ring cover. 6. Remove the nut. 7. Remove the upper trim pillar (24396). Installation 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Trim Panel-Upper Quarter TRIM PANEL-UPPER QUARTER Removal Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7863 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 (52018). 5. Remove the rear seat shoulder strap opening bezel. 6. Remove the pin-type retainer. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7864 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > NHTSA00V200000 > Jul > 00 > Recall 00V200000: Jack Use, Stowage, & Warning Revisions Jack: Recalls Recall 00V200000: Jack Use, Stowage, & Warning Revisions Vehicle Description: Passenger vehicles. These vehicles have jacking instructions which, if followed, could cause the vehicle operator to place the jack on a frame weld when attempting to raise a rear wheel. If the vehicle is jacked up with the jack placed on the frame weld and if the vehicle is free to roll (wheels not blocked or chocked), the jack could yield and the vehicle may drop suddenly. If this occurs and any portion of the operator's body is under the vehicle, the potential for personal injury exists. Owners will be provided with a revised Jack Instruction and Stowage Card and Jack Warning Label, as well as a supplement to the owner guide. Owner notification began July 24, 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 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). 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7877 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7878 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7879 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7880 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7881 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7882 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7883 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > NHTSA00V200000 > Jul > 00 > Recall 00V200000: Jack Use, Stowage, & Warning Revisions Jack: All Technical Service Bulletins Recall 00V200000: Jack Use, Stowage, & Warning Revisions Vehicle Description: Passenger vehicles. These vehicles have jacking instructions which, if followed, could cause the vehicle operator to place the jack on a frame weld when attempting to raise a rear wheel. If the vehicle is jacked up with the jack placed on the frame weld and if the vehicle is free to roll (wheels not blocked or chocked), the jack could yield and the vehicle may drop suddenly. If this occurs and any portion of the operator's body is under the vehicle, the potential for personal injury exists. Owners will be provided with a revised Jack Instruction and Stowage Card and Jack Warning Label, as well as a supplement to the owner guide. Owner notification began July 24, 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 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). 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7893 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7894 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7895 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7896 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7897 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7898 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7899 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7906 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7907 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7908 ^ 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7909 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7910 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 7911 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 7912 Door Lock Cylinder: Service and Repair REMOVAL 1. Remove the exterior door handle. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 7917 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the driver door panel. 3. Position weather shield aside. 4. Remove the keyless entry keypad. 1 Remove the Clip and remove the keyless entry keypad. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions Keyless Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions > Page 7921 Keyless Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions > Page 7922 Keyless Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service Precautions > Page 7923 Keyless Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Programming Transmitter Keyless Entry Transmitter: Service and Repair Programming Transmitter 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. NOTE: Keyless entry remote transmitters can also be programmed using a scan tool and the Ford Service Function (FSF) card. 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Programming Transmitter > Page 7928 Keyless Entry Transmitter: Service and Repair Autolock and Horn Chirp Programming 1. Turn the ignition switch to RUN. NOTE: This procedure must be completed within 30 seconds. 2. Press the UNLOCK button three times. 3. Turn the ignition switch to OFF. 4. Press the UNLOCK button three times. 5. Turn the ignition switch to RUN. The doors Will lock and unlock to confirm entry into program mode. 6. Press the UNLOCK button once to toggle the Autolock feature on or off; or twice to toggle the Horn Chirp function on or off. The horn will chirp to confirm toggling of the Autolock feature. 7. Exit program mode by turning the ignition to OFF, START, or wait 7.5 seconds. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Testing and Inspection Power Door Lock Actuator: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Testing and Inspection > Page 7933 Power Door Lock Actuator: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the latch. For additional information, refer to Door 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7939 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7940 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Power Door Lock Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Power Door Lock Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 7958 Power Door Lock Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 7959 Power Door Lock Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 7960 Power Door Lock Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 7961 Power Door Lock Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 7966 Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > LF Door Lock Switch > Page 7967 Schematic Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Page 7968 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7973 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7974 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7975 ^ 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7976 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7977 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 7978 Trunk / Liftgate Lock Cylinder: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 7979 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7989 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7990 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7991 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7992 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7993 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7994 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7995 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7996 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7997 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7998 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7999 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 Power Mirror Control Module: Electrical Diagrams For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations > Page 8004 Power Mirror Motor: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Mirrors; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations > Page 8005 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8009 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8010 Power Mirror Switch: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8011 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8012 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8013 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes VC Label - USA (Typical) VC Label-Incomplete Vehicle (Typical) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8019 VC Label - Canada (Typical) VC Label - Mexico (Typical) The upper portion of the vehicle certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement and the VIN. It also includes gross vehicle weight ratings (GVWR). The VC label is located on the left-hand front door jamb. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8020 Paint Code The first set of numbers/letters listed indicate the vehicle primary body color code. The second set of letters/numbers listed (if applicable), indicate a two-tone or accent body color code. FL - Toreador Red (clear coat) - TS - Silver Frost (clear coat) - UA - Ebony (clear coat) - WT - Performance White (clear coat) - FS - Spruce Green - TP - Medium Gray - B2 - Harvest Gold - M7 - Light Metallic Blue (clear coat) - LL - Deep Wedgewood Blue (clear coat) - SU - Amazon Green - B4 - Chestnut (clear coat) - LK - Dark Blue (police/fleet) - LM - Michigan Blue (police/fleet) - MM - Ultra Blue (police/fleet), clear coat - LN - Light Blue Metallic (police/fleet) - TM - Light Gray (police/fleet) - TN - Silver Gray Metallic (police/fleet) - YG - Medium Titanium (police/fleet) - B1 - Police Cream Yellow (police/fleet) - BU - Medium Brown Metallic (police/fleet) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8021 Tape and Paint Stripe Code Tape and paint stripe codes do not apply to all vehicle. If applicable, the code(s) is as follows: C - Chestnut - J - Medium Red - P - Light Charcoal - Q - Dark Blue - B - Black Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8022 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions Keyless Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 8027 Keyless Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 8028 Keyless Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service Precautions > Page 8029 Keyless Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 8035 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 VIN W (2000)) 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 8036 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 VIN W (2000)) 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 8037 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 VIN W (2000)) 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 8038 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8039 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8040 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 VIN W (2000)) 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 8041 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 VIN W (2000)) 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 8042 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 VIN W (2000)) 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 8043 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 VIN W (2000)) 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 8044 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 VIN W (2000)) 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 8045 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 VIN W (2000)) 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 8046 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8047 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8048 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8049 Power Door Lock Control Module: Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8050 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8051 Power Door Lock Control Module: Electrical Diagrams Diagram 57-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8052 Diagram 57-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8053 Diagram 57-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 8054 Power Door Lock Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 8055 Power Door Lock Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 8056 Power Door Lock Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 8057 Power Door Lock Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8066 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8067 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8068 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8069 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8070 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8071 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 Power Mirror Control Module: Electrical Diagrams For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 Power Seat Control Module: Electrical Diagrams For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8105 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 Power Seat Control Module: Electrical Diagrams For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 8122 Power Seat Motor: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 8123 Power Seat Motor: Service and Repair REMOVAL 1. Remove the seat. For additional information, refer to Seat-Front Power. See: Service and Repair/Seat - Front Power 2. Remove the seat track. For additional information, refer to Seat-Track. See: 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver Seat Control Switch Power Seat Switch: Diagrams Driver Seat Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver Seat Control Switch > Page 8128 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch Power Seat Switch: Testing and Inspection Driver Seat Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8131 Terminals Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8132 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8133 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8134 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8135 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Regulator Control Switch Power Seat Switch: Service and Repair Seat Regulator Control Switch REMOVAL 1 Disconnect the battery. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Regulator Control Switch > Page 8138 Power Seat Switch: Service and Repair Front Seat Occupied Switch REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the seat. 3. Remove the seat track. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat-Front Cushion and Frame Seat Cushion: Service and Repair Seat-Front Cushion and Frame 1. Remove the seat. 2. Remove the seat track. For additional information, refer to 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat-Front Cushion and Frame > Page 8143 8. Remove the armrest. 9. Remove the armrest cover trim. 10. Remove the frame. 11. Remove the bolts. 12. Remove the seat occupy switch. For additional information, Switch-Front Seat Occupied. 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat-Front Cushion and Frame > Page 8144 Seat Cushion: Service and Repair Seat - Front Seat Backrest, Pad and Frame DISASSEMBLY 1. Remove the seat. 2. Release the J retainer. 3. Release the J retainer. 4. Disconnect the connector. 5. Remove the bolts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat-Front Cushion and Frame > Page 8145 6. Remove the bolt. 7. Remove the headrest retainer covers. 8. Release the clip. 9. Remove the trim cover. ASSEMBLY Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat-Front Cushion and Frame > Page 8146 1. To assemble, reverse the disassembly procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service Precautions Seat Latch: Service Precautions WARNING: THE INERTIA FRONT SCAT 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 BACKRESTS 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service Precautions > Page 8150 Seat Latch: Description and Operation WARNING: THE INERTIA FRONT SCAT 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 BACKRESTS 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions Seat Track: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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. Remove the front seat. 2. Disconnect the connector. 3. Remove the nut. 4. Pull the buckle through the cushion opening. 5. Release the J retainer. 6. Release the J retainer. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8156 7. Remove the bolts. 8. Remove the pivot bolt. 9. Disconnect the connector. 10. Remove the bolts. INSTALLATION Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8157 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8158 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8159 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Side Only > Page 8160 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Lumbar Seats <--> [Vacuum/Pressure Pump, Seats] > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair Vacuum/Pressure Pump Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the seat. 3. Remove the cover. 4. Remove the screws. 5. Disconnect the connector. 6. Disconnect the vacuum tubes. NOTE: Mark the tubes before disconnecting. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Lumbar Seats <--> [Vacuum/Pressure Pump, Seats] > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair > Page 8165 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8176 Power Door Lock Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 8177 Schematic Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 8178 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8182 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8183 Power Mirror Switch: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8184 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8185 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8186 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Control Switch Power Seat Switch: Diagrams Driver Seat Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Control Switch > Page 8191 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch Power Seat Switch: Testing and Inspection Driver Seat Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8194 Terminals Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8195 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8196 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8197 Power Seat Switch: Testing and Inspection Passenger Seat Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Control Switch > Page 8198 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Regulator Control Switch Power Seat Switch: Service and Repair Seat Regulator Control Switch REMOVAL 1 Disconnect the battery. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Regulator Control Switch > Page 8201 Power Seat Switch: Service and Repair Front Seat Occupied Switch REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the seat. 3. Remove the seat track. For additional information, refer to 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 VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Description and Operation Power Trunk / Liftgate Lock Switch: Description and Operation Refer to Keyless Entry. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair Vacuum/Pressure Pump Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the seat. 3. Remove the cover. 4. Remove the screws. 5. Disconnect the connector. 6. Disconnect the vacuum tubes. NOTE: Mark the tubes before disconnecting. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair > Page 8208 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is comprised of urethane, PVC, and recycled felt. Insulation is installed: - under the roof panel. - above and below the instrument panel. - on the cowl sides. - over the front and rear floor areas. - in the B-pillar and C-pillar sections. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 8216 Brake Switch (Cruise Control): Adjustments NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled. For additional information, refer to Brake Switch (Cruise Control). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 8217 Brake Switch (Cruise Control): Service and Repair 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 ml) or more to relearn its strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Bracket To Speed Control Servo Screw 8-11 Nm Speed Control Servo Nut 5-7 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8227 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8228 Cruise Control Servo: Service and Repair REMOVAL 1. Remove the speed control actuator cable. Refer to Cruise Control Servo 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 VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 8229 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications Cruise Control Servo Cable: Specifications Battery Ground Cable........................................................................................................................... .....................................................................7-10 N.m Bracket to Speed Control Servo Screw........... ...........................................................................................................................................................8 -11 N.m Engine Cover Nut................................................................................................................... ....................................................................................6-10 N.m Speed Control Actuator Cable-to-Accelerator Cable Bracket Bolt..............................................................................................................................3-4 N.m Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8233 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 VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8234 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 from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. 4. Remove the speed control actuator cable from the speed control servo pulley. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8235 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and 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: ^ Make sure 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. 4. Connect the speed control actuator cable to the throttle lever. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 8236 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. Refer to Cable Adjustment. See: Adjustments 6. Install the engine cover. 1 Position the engine cover. 2 Install the nut. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Page 8240 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. For additional information refer to Steering. 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 VIN W (2000)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 8249 Brake Switch (Cruise Control): Adjustments NOTE: For proper adjustment, the deactivator switch must be removed and reinstalled. For additional information, refer to Brake Switch (Cruise Control). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 8250 Brake Switch (Cruise Control): Service and Repair 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 ml) or more to relearn its strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Page 8257 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. For additional information refer to Steering. 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Conventional ABS Light: Description and Operation Conventional Anti-Lock Brakes The anti-lock brake warning indicator illuminates when the anticlock brake control module detects a fault in the system. For further information regarding this component and the system that it is a part of, please refer to; Brakes and Traction Control/ Testing and Inspection. Brake System 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. For additional information, refer to Brake Warning Indicator. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Conventional > Page 8263 ABS Light: Description and Operation Electronic Anti-Lock Brakes The anti-lock brake warning indicator is located in the indicator lamp module and illuminates when the anti-lock brake control module detects a fault in the system. Brake System The brake system warning indicator is located in the indicator lamp module and 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. For additional information, refer to Brake Warning Indicator. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 8272 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 VIN W (2000)) 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 VIN W (2000)) 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 8278 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8281 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8284 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8285 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8286 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8287 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8288 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8291 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8292 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8293 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8294 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8295 Audible Warning Device: Electrical Diagrams Diagram 66-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8296 Diagram 66-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 8297 Audible Warning Device: Description and Operation 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 8298 Audible Warning Device: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection; Warning Devices. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Belt Minder Deactivation/Activation Audible Warning Device: Service and Repair Belt Minder Deactivation/Activation PREPARATION 1. Before deactivating/activating the belt minder, set the parking brake. 2. Place the gearshift in P (Park) (automatic transmission) or the neutral position (manual transmission). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver safety belt. 6. Place the parklamps/headlamps switch in the OFF position. (If the vehicle is equipped with Autolamps, this will not affect the procedure.) Deactivating/Activating 1. Turn the ignition switch to the RUN position. (Do not start the engine.) 2. Wait until the safety belt warning lamp turns off. (approximately one to two minutes) 3. Buckle then unbuckle the safety belt three times, ending with the safety belt unbuckled. This portion of the procedure can be done before or during belt minder warning activation. NOTE: Steps 3 through 5 must be completed within 60 seconds or the procedure must be repeated. 4. Turn the parklamps/headlamps on then off. 5. Buckle then unbuckle the safety belt three times ending with the safety belt unbuckled. After this step the safety belt warning lamp will be illuminated for three seconds. 6. Within seven seconds of the safety belt warning lamp turning off, buckle then unbuckle the safety belt. This will enable the belt minder if disabled or disable the belt minder if enabled. 7. The following sequence of events confirm the belt minder is enabled: - flashing of the safety belt warning belt lamp four times per second for three seconds - three seconds with the safety belt lamp off - flashing the safety belt lamp four times per second for three seconds again 8. The safety belt lamp flashing four times per second for three seconds provides confirmation that the belt minder is disabled. 9. After confirmation, the deactivation/activation procedure is complete. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Belt Minder Deactivation/Activation > Page 8301 Audible Warning Device: Service and Repair Key-In-Ignition Warning Switch REMOVAL 1. Remove the ignition lock cylinder. 1 Insert the key into the ignition 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service Precautions Audible Warning Device Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service Precautions > Page 8305 Audible Warning Device Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service Precautions > Page 8306 Audible Warning Device Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service Precautions > Page 8307 Audible Warning Device Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Conventional Brake Warning Indicator: Description and Operation Conventional Anti-Lock Brakes The anti-lock brake warning indicator illuminates when the anticlock brake control module detects a fault in the system. For further information regarding this component and the system that it is a part of, please refer to; Brakes and Traction Control/ Testing and Inspection. Brake System 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Conventional > Page 8312 Brake Warning Indicator: Description and Operation Electronic Anti-Lock Brakes The anti-lock brake warning indicator is located in the indicator lamp module and illuminates when the anti-lock brake control module detects a fault in the system. Brake System The brake system warning indicator is located in the indicator lamp module and 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Conventional Charge Lamp/Indicator: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Conventional > Page 8317 Charge Lamp/Indicator: Description and Operation Electronic 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8322 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8325 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8326 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8329 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 Diagram 44-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8345 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8346 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8347 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 Diagram 44-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 8357 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 VIN W (2000)) 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 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8360 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8361 Clock: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 8362 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 8363 73 Digital Multimeter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service Precautions Compass: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service Precautions > Page 8367 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 VIN W (2000)) 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 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8370 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8371 Compass: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8372 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8373 B3 - B4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8374 73 Digital Multimeter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment 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 bold 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 8377 Compass: Adjustments 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. Refer to Vehicle Demagnetizing See: Service and Repair/Vehicle Demagnetizing Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Display and Module Compass: Service and Repair Display and Module NOTE: The compass display and module are integral to the inside rear view mirror and not replaced separately. For additional information, refer to Mirrors. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Display and Module > Page 8380 Compass: Service and Repair 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 1 meter (3 ft) 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; refer to Compass Zone Adjustment. See: Adjustments/Compass Zone Adjustment 4. Perform the calibration adjustment procedure; refer to Calibration Adjustment. See: Adjustments/Calibration Adjustment Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Page 8381 73 Digital Multimeter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8387 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8388 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8389 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8390 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8391 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 8395 Driver/Vehicle Information Display: Description and Operation The message center information is integrated in the electronic instrument cluster. The instrument cluster receives the needed message center signals from the Vehicle Speed Sensor (VSS), fuel level sensor (part of the fuel pump module), and the Powertrain Control Module (PCM). The message center information can be toggled by pressing the appropriate message center switch. The message center display proves out when the instrument cluster prove-out, when the ignition switch is turned to the ON position. The message center then resumes the mode of operation last used. The message center displays are as follows: - average fuel economy (AVG ECON) - average speed (AVG SPEED) - distance to empty (DIST TO EMPTY) - instantaneous fuel economy (INST ECON) - trip distance A (TRIP A) - trip distance B (TRIP B) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 8396 Driver/Vehicle Information Display: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center switch Driver/Vehicle Information Display: Service and Repair Message Center switch REMOVAL 1. Remove the instrument cluster finish panel. Refer to Dash Board. 2. Remove the message center switch. 1 Remove the screws. 2 Remove the message center switch. - Install new illumination bulbs as necessary. NOTE: The illumination bulbs are replaceable. INSTALLATION 1. To install, reverse the removal procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8399 73III Automotive Meter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Conventional Fuel Gauge: Testing and Inspection Conventional The fuel gauge receives the fuel level resistance from the fuel level sensor, part of the fuel pump module. To prevent the fuel gauge pointer from fluctuating as a result of excessive movement of fuel in the fuel tank, the fuel indicator module provides a delay to the fuel gauge. If the fuel level is low, the resistance in the fuel level sensor will be low, causing the gauge to indicate empty (E). When the fuel level is high, the resistance in the fuel level sensor is high, and the gauge indicates full (F). The fuel gauge and the fuel indicator module must be replaced together. The fuel indicator module also turns on the low fuel indicator when the fuel gauge shows approximately one-eighth of a tank of fuel remaining or less. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Conventional > Page 8404 Fuel Gauge: Testing and Inspection Electronic The fuel level is displayed on a digital bar gauge using eight bars top to bottom. Fuel remaining is displayed in the fuel/temperature gauge. For fuel levels greater than 70 liters (18 gal), the letter F (full) is displayed. For fuel levels less than 3 liters (2 gal), the letter E (empty) is displayed. The digital displays are based on varying current flow from the fuel level sensor. The instrument cluster also contains self diagnostics for the fuel gauge. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure 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: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the ECS fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the electronic crash sensor (ECS) module to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8413 Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation 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: To reduce the risk of personal injury, do not use any memory saver devices. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the electronic crash sensor (ECS) module fuses F18 (10A) and F10 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 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 air bag sensor, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. 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). 6. Disconnect the battery ground cable (14301) and wait at least one minute. 7. Remove the two back cover plugs from the steering wheel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8414 8. Remove the two driver air bag module bolts (one shown). 9. Disconnect and 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. 10. Attach the restraint system diagnostic tool 418-F088 to the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment and disconnect the glove compartment isolator. 12. Push in on the glove compartment door tabs and position downward. 13. Disconnect the passenger air bag module electrical connector. 14. Attach the restraint system diagnostic tool 418-F088 to the vehicle harness side of the passenger air bag module electrical connector. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8415 15. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB. 16. Connect the battery ground cable. Reactivation 1. Remove the ECS module fuses F18 (10A) and F10 (10A) from the central junction box (CJB). 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector and connect the passenger air bag module electrical connector. 4. Connect the glove compartment isolator. 5. Close the glove compartment door. 6. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 7. Connect and position the driver air bag module. 1. Connect the driver air bag module electrical connector. 2. Connect the horn switch electrical connector. 3. Position the driver air bag module to the steering wheel. 8. Install the two driver air bag module bolts (one shown). 9. Install the steering wheel two back cover plugs. 10. Turn the ignition switch from OFF to ON. 11. Install the ECS module fuses F18 (10A) and F10 (10A) to the CJB and install the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 12. Connect the battery ground cable. 13. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8416 - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8417 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Warning Indicator Bulb Instrument Panel Bulb: Service and Repair Warning Indicator Bulb 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Warning Indicator Bulb > Page 8422 Instrument Panel Bulb: Service and Repair Warning Indicator Bulb-Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Conventional Low Fuel Lamp/Indicator: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Conventional > Page 8427 Low Fuel Lamp/Indicator: Description and Operation Electronic The low fuel level warning indicator flashes when approximately one-eighth tank of fuel or less is remaining. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 8428 Low Fuel Lamp/Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 8432 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Conventional Odometer: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Conventional > Page 8440 Odometer: Description and Operation Electronic The odometer displays seven digits with the last digit in tenths of a unit. The odometer range is limited by instrument cluster memory space. The S symbol on the odometer indicates that the original odometer mileage is unknown. If the actual mileage can be verified, an authorized repair facility can program a replacement odometer to reflect the correct mileage. The message ERROR indicates that the instrument cluster cannot read a valid odometer memory from the non-volatile random access memory. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 8441 Odometer: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 8448 Oil Pressure Warning Lamp/Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions Audible Warning Device Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions > Page 8453 Audible Warning Device Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions > Page 8454 Audible Warning Device Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service Precautions > Page 8455 Audible Warning Device Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder Seat Belt Reminder Lamp: Description and Operation Belt Minder Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder > Page 8463 Seat Belt Reminder Lamp: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder > Page 8464 Seat Belt Reminder Lamp: Description and Operation Electronic The safety belt warning indicator is directly hardwired to the Lighting Control Module (LCM). The LCM controls the safety belt warning indicator depending on the signal it receives from the safety belt buckle switch. The safety belt warning indicator illuminates when the safety belt is not buckled, closing the safety belt buckle switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt Minder > Page 8465 Seat Belt Reminder Lamp: Description and Operation Warning Devices NOTE: The belt minder feature is configurable. If configuring using a scan tool, refer to Module Communications Network (Information Bus). To configure without using a scan tool, refer to Belt Minder Deactivation/Activation. The belt minder feature supplements the current safety belt warning function. The belt minder feature is enabled after the current safety belt warning is complete. If the driver safety belt is not buckled approximately five seconds after the safety belt warning light has turned off, the belt minder reminds the driver that their safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. While activated, the belt minder alternates the chime and indicator from on for 6 seconds to off for 30 seconds. The belt minder reminder stops when: - the driver safety belt is buckled. - the ignition is turned to OFF or ACC. - five minutes have elapsed since belt minder has started. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 8466 Seat Belt Reminder Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Conventional Speedometer Head: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Conventional > Page 8475 Speedometer Head: Description and Operation Electronic The speedometer 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 8476 Speedometer Head: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Suspension Warning Indicator > Component Information > Description and Operation > Page 8480 Suspension Warning Indicator: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Conventional Temperature Gauge: Description and Operation Conventional 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 VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Conventional > Page 8485 Temperature Gauge: Description and Operation Electronic 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 200 ohms to 13,000 ohms. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 8486 Temperature Gauge: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations > Page 8490 Temperature Sensor (Gauge): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations > Page 8491 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 8496 Ambient Light Sensor: Service Precautions CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel to expose the connector without stretching the wiring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 8497 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 8510 (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 VIN W (2000)) 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 VIN W (2000)) 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 8516 (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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Brake Lamp: Electrical Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > System Description Brake Lamp: Description and Operation System Description NOTE: The stoplamps are powered from the Brake Pedal Position (BPP) switch directly, not from the 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 form 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > System Description > Page 8536 Brake Lamp: Description and Operation Principles of Operation (How Does It Work?) NOTE: The stoplamps are powered from the Brake Pedal Position (BPP) switch directly, not from the 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 form 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview 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 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If scan tool does not communicate with the vehicle: 1 Check that the program card is correctly installed. 2 Check the connections to the vehicle. 3 Check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool Manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. IF scan tool responds with: 1 CKT914, CKT915 or CKT 70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). 2 NO RESP/NOT EQUIP for the DDM, go to Keyless Entry. 3 SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the DDM. 6. If the DTCs retrieved are related to the concern, go to the DDM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If not 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8539 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8540 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8541 Brake Lamp: Pinpoint Tests Test K: Stoplamps Are Inoperative K1 - K2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8542 K3 - K4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8543 K5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8544 K6 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8545 L1 - L2 Test M: Stoplamps Are On Continuously Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8546 M1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8547 M2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8548 M3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8549 Brake Lamp: Scan Tool Testing and Procedures Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 8550 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 8559 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pedal Position Switch: > 03-20-3 > Oct > 03 > Customer Interest for Brake Pedal Position 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pedal Position Switch: > 03-20-3 > Oct > 03 > Customer Interest for Brake Pedal Position Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 8569 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pedal Position Switch: > Page 8570 Temperature Sensor (Gauge): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pedal Position Switch: > Page 8571 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Locations Temperature Sensor (Gauge): Locations Note: Engine Coolant Temperature Sender is located on the top RH front of engine, near fuel injector #1. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Locations > Page 8574 Temperature Sensor (Gauge): Service and Repair Sender Unit - Water Temperature Indicator Removal 1. Partially drain the engine cooling system. 2. Remove the engine appearance cover. 3. 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Locations > Page 8575 2. Install the engine appearance cover. 3. Fill the engine cooling system. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes VC Label - USA (Typical) VC Label-Incomplete Vehicle (Typical) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > System Information > Application and ID > Paint Codes > Page 8579 VC Label - Canada (Typical) VC Label - Mexico (Typical) The upper portion of the vehicle certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement and the VIN. It also includes gross vehicle weight ratings (GVWR). The VC label is located on the left-hand front door jamb. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > System Information > Application and ID > Paint Codes > Page 8580 Paint Code The first set of numbers/letters listed indicate the vehicle primary body color code. The second set of letters/numbers listed (if applicable), indicate a two-tone or accent body color code. FL - Toreador Red (clear coat) - TS - Silver Frost (clear coat) - UA - Ebony (clear coat) - WT - Performance White (clear coat) - FS - Spruce Green - TP - Medium Gray - B2 - Harvest Gold - M7 - Light Metallic Blue (clear coat) - LL - Deep Wedgewood Blue (clear coat) - SU - Amazon Green - B4 - Chestnut (clear coat) - LK - Dark Blue (police/fleet) - LM - Michigan Blue (police/fleet) - MM - Ultra Blue (police/fleet), clear coat - LN - Light Blue Metallic (police/fleet) - TM - Light Gray (police/fleet) - TN - Silver Gray Metallic (police/fleet) - YG - Medium Titanium (police/fleet) - B1 - Police Cream Yellow (police/fleet) - BU - Medium Brown Metallic (police/fleet) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > System Information > Application and ID > Paint Codes > Page 8581 Tape and Paint Stripe Code Tape and paint stripe codes do not apply to all vehicle. If applicable, the code(s) is as follows: C - Chestnut - J - Medium Red - P - Light Charcoal - Q - Dark Blue - B - Black Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > System Information > Application and ID > Paint Codes > Page 8582 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Specifications > Page 8585 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Specifications > Page 8586 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Component Information > Specifications > Page 8587 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position Sensor. 1 Disconnect the electrical connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling High Mounted Stoplamp: 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 8596 (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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stoplamp: 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8602 (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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 8603 High Mounted Stoplamp: Specifications High Mounted Stoplamp Screws 1 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 8604 High Mounted Stoplamp: Description and Operation 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 8605 High Mounted Stoplamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Brake Lamp; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 8606 High Mounted Stoplamp: 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8611 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8612 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8613 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 Diagram 91-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 8626 Cornering Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Turn Signals; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 Courtesy Lamp: Electrical Diagrams Except Police Diagram 89-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 Diagram 89-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Diagram 89-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 Diagram 89-4 Police Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8649 Diagram 89-1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8650 Diagram 89-2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 Diagram 89-3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 Diagram 89-4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8653 Diagram 89-5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Description and Operation > System Description Courtesy Lamp: Description and Operation System Description The interior lighting can be separated into two distinct modes of operation, the courtesy lighting, and the demand lighting. The Lighting Control Module (LCM) controls all of the interior lighting in the vehicle, in the following text. The front dome lamps, rear reading lamps, and instrument panel courtesy lamps, can be illuminated either by opening any of the vehicle doors (courtesy lamp function) or by depressing the headlamp switch (demand lamp function). When any door is open, the door ajar switch grounds an input to the LCM which then sends power to the courtesy lamps. The voltage sent to the courtesy lamps gradually increases from 0 volts to 12 volts within 500 ms (± 50 ms), to achieve the theater lighting effect. When the door(s) are closed the door ajar switch(es) break(s) the ground to the LCM input which then gradually reduces the power from 12 volts to 0 volts within 5 seconds.(±.5 second). When the headlamp switch is depressed it grounds an input the LCM which in turn sends 12 volts to the front dome lamps, rear reading lamps, and instrument panel courtesy lamps. When the headlamp switch is depressed a second time, it breaks the ground to the LCM input which then ceases to send power to the front dome lamps, rear reading lamps, and instrument panel courtesy lamps. The front map lamps, rear reading lamps, glove compartment lamp, vanity mirror lamp, luggage compartment lamp, and engine compartment lamp, (police and natural gas vehicles only) are provided with power by the LCM demand lighting output, and are illuminated when a dedicated switch closes, completing the ground circuit for the appropriate lamp(s). As the LCM provides constant power to the demand lamps, there is no ramp up or ramp down time, the illumination is instantaneous once the appropriate switch is closed. When a door handle is lifted, or a keypad button is depressed, it grounds an input to the LCM which then illuminates the interior lighting using the theater lighting feature. When the unlock button on a remote keyless entry transmitter is depressed, the DDM sends a pulse signal to the LCM which then illuminates the interior lighting using the theater lighting feature. In either instance the interior lamps will extinguish after the time-out using the theater lighting feature. If a lock button on the remote keyless entry transmitter is depressed, or the ignition is turned to the run or acc position, it will extinguish the interior lamps prior to the end of the time-out. The dark car feature is a special order option that offers deletion of the illuminated entry function on police vehicles. Upon vehicle power-up, the LCM will monitor the dark car input signal for a ground condition of longer than two seconds. If the ground is present, no interior lighting will be provided during entry or exit of the vehicle. The interior lighting will, however, still operate on demand whenever the dome lamp switch is depressed. A ground will be provided to the LCM by an on-line connector within the unique police 14401 instrument panel harness. The male terminal side connector will be retained on a portable clip and the female terminal connector will be tear-taped to a bundle. If the dark car feature is required, the connection will be made on the assembly line. If no connection is made the default state of the LCM will be to provide illuminated entry. The vehicle can be reconfigured by removing the power to the module, changing the dark car input from (or to) a ground or an open circuit, and then reapplying power to the module. The vehicle can also be reconfigured by changing the dark car input signal from (or to) a ground or an open circuit, entering diagnostics, and then exiting diagnostics. The battery saver will disrupt power to the courtesy lamps after 10 minutes, the demand lamps after 30 minutes, and the headlamps after 10 minutes. Turning the ignition switch to the run or acc position will terminate the battery saver feature by disabling the interrupt timers and reinstate power to the lamps. A reset event will set the courtesy lamps interrupt timer to zero. The reset events for the courtesy lamps interrupt timer are; turning on the courtesy lamps by using the dome lamp switch, opening any door (as detected by the door ajar switches). A reset event will set the demand lamps interrupt timer to zero. The reset events for the demand lamps interrupt timer are; opening the luggage compartment door, opening any door (as detected by the door ajar switches) When the panic button on a keyless entry remote transmitter is pressed, or an anti-theft system violation occurs, the panic alarm or anti-theft alarm function will override the courtesy lamps, demand lamps and headlamps battery saver functions for the duration of the alarm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Description and Operation > System Description > Page 8656 Courtesy Lamp: Description and Operation Principles of Operation (How Does It Work?) The interior lighting can be separated into two distinct modes of operation, the courtesy lighting, and the demand lighting. The Lighting Control Module (LCM) controls all of the interior lighting in the vehicle, in the following text. The front dome lamps, rear reading lamps, and instrument panel courtesy lamps, can be illuminated either by opening any of the vehicle doors (courtesy lamp function) or by depressing the headlamp switch (demand lamp function). When any door is open, the door ajar switch grounds an input to the LCM which then sends power to the courtesy lamps. The voltage sent to the courtesy lamps gradually increases from 0 volts to 12 volts within 500 ms (± 50 ms), to achieve the theater lighting effect. When the door(s) are closed the door ajar switch(es) break(s) the ground to the LCM input which then gradually reduces the power from 12 volts to 0 volts within 5 seconds.(±.5 second). When the headlamp switch is depressed it grounds an input the LCM which in turn sends 12 volts to the front dome lamps, rear reading lamps, and instrument panel courtesy lamps. When the headlamp switch is depressed a second time, it breaks the ground to the LCM input which then ceases to send power to the front dome lamps, rear reading lamps, and instrument panel courtesy lamps. The front map lamps, rear reading lamps, glove compartment lamp, vanity mirror lamp, luggage compartment lamp, and engine compartment lamp, (police and natural gas vehicles only) are provided with power by the LCM demand lighting output, and are illuminated when a dedicated switch closes, completing the ground circuit for the appropriate lamp(s). As the LCM provides constant power to the demand lamps, there is no ramp up or ramp down time, the illumination is instantaneous once the appropriate switch is closed. When a door handle is lifted, or a keypad button is depressed, it grounds an input to the LCM which then illuminates the interior lighting using the theater lighting feature. When the unlock button on a remote keyless entry transmitter is depressed, the DDM sends a pulse signal to the LCM which then illuminates the interior lighting using the theater lighting feature. In either instance the interior lamps will extinguish after the time-out using the theater lighting feature. If a lock button on the remote keyless entry transmitter is depressed, or the ignition is turned to the run or acc position, it will extinguish the interior lamps prior to the end of the time-out. The dark car feature is a special order option that offers deletion of the illuminated entry function on police vehicles. Upon vehicle power-up, the LCM will monitor the dark car input signal for a ground condition of longer than two seconds. If the ground is present, no interior lighting will be provided during entry or exit of the vehicle. The interior lighting will, however, still operate on demand whenever the dome lamp switch is depressed. A ground will be provided to the LCM by an on-line connector within the unique police 14401 instrument panel harness. The male terminal side connector will be retained on a portable clip and the female terminal connector will be tear-taped to a bundle. If the dark car feature is required, the connection will be made on the assembly line. If no connection is made the default state of the LCM will be to provide illuminated entry. The vehicle can be reconfigured by removing the power to the module, changing the dark car input from (or to) a ground or an open circuit, and then reapplying power to the module. The vehicle can also be reconfigured by changing the dark car input signal from (or to) a ground or an open circuit, entering diagnostics, and then exiting diagnostics. The battery saver will disrupt power to the courtesy lamps after 10 minutes, the demand lamps after 30 minutes, and the headlamps after 10 minutes. Turning the ignition switch to the run or acc position will terminate the battery saver feature by disabling the interrupt timers and reinstate power to the lamps. A reset event will set the courtesy lamps interrupt timer to zero. The reset events for the courtesy lamps interrupt timer are; turning on the courtesy lamps by using the dome lamp switch, opening any door (as detected by the door ajar switches). A reset event will set the demand lamps interrupt timer to zero. The reset events for the demand lamps interrupt timer are; opening the luggage compartment door, opening any door (as detected by the door ajar switches) When the panic button on a keyless entry remote transmitter is pressed, or an anti-theft system violation occurs, the panic alarm or anti-theft alarm function will override the courtesy lamps, demand lamps and headlamps battery saver functions for the duration of the alarm. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Courtesy Lamp: Initial Inspection and Diagnostic Overview NOTE: The LCM must be reconfigured upon replacement. Refer to Module Communications Network (Information Bus). 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If the concern remains after the inspection connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST.If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESP/NOT EQUIP for LCM, go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the Module - LCM ^ NO RESP/NOT EQUIP for DDM, go to Pinpoint Test O. See: Pinpoint Tests/Test O: No Communication With the Module-DDM ^ SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and perform self test diagnostics for the LCM and DDM modules. 6. If the DTCs retrieved are related to the concern, go to the LCM or DDM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/Driver Door Module (DDM) Diagnostic Trouble Code (DTC) Index 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8659 Courtesy Lamp: Diagnostic Trouble Code Descriptions Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8660 Part 1 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8661 Part 2 Of 2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8662 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8663 Courtesy Lamp: Pinpoint Tests A1 - A2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8664 A3 Test B: No Communication With the Module-Unable to Enter LCM Self Test Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8665 B1 - B2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8666 B3 - B4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8667 B5 Test C: Courtesy Lamps Are Inoperative C1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8668 C2 - C5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8669 C6 - C7 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8670 C8 - C9 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8671 C10 - C11 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8672 C12 - C13 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8673 D1 - D2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8674 E1 - E3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8675 F1 - F2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8676 G1 - G3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8677 G4 Test H: Illuminated Entry Inoperative When Using Remote Transmitter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8678 H1 - H3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8679 H4 - H5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8680 H6 - H7 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8681 H8 - H9 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8682 H10 - H11 Test J: Illuminated Entry Is Inoperative When Using the Keypad - Keypad Backlighting Is In Operative Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8683 J1 - J2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8684 J3 - J4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8685 J5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8686 K1 - K2 Test L: B1445 or B1442: Door Handle Switch Failure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8687 L1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8688 L2 - L3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8689 L4 - L5 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8690 M1 - M4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8691 N1 - N2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8692 N3 - N4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8693 O1 - O2 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8694 Courtesy Lamp: Scan Tool Testing and Procedures Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8695 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8696 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 8697 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications DRL Module Bolt 3 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8702 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8703 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8704 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)Daytime Running Lamps or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 8713 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 VIN W (2000)) 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 VIN W (2000)) 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 8719 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome/MAP Lamp Dome Lamp: Service and Repair Dome/MAP Lamp 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome/MAP Lamp > Page 8722 Dome Lamp: Service and Repair Rear Reading Lamp Assembly REMOVAL 1. Rotate both reading lamps to the stop position, then continue until both reading lamps are in the vertical position. 2. Remove the screws. 3. Remove the reading lamp assembly. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 8731 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 VIN W (2000)) 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 8732 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 8738 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 VIN W (2000)) 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 8739 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Page 8740 Exterior Lighting Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Exterior 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8749 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 Exterior 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Exterior Lighting Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 Exterior Lighting Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8759 Exterior Lighting Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8760 Exterior Lighting Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8761 Exterior Lighting Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8762 Exterior Lighting Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch Hazard Flasher Relay: Locations Maltifunction Switch Hazard Flasher Relay is replaced by the Multifunction switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8768 View 151-6 Multifunction Switch Locations See: Hazard Warning Switch Description and Operation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8769 Connector View See: Diagrams Diagrams by Numbers, Diagram Set 90 Electrical Diagram Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8770 Hazard Flasher Relay: Locations Emergency Flasher Relays #1 and #2 (Police Option) Left hand rear of the luggage compartment, inside the emergency flasher relay block. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8771 Hazard Flasher Relay: Locations Rear Flasher Relay (Police Option) Center rear of the luggage compartment, on rear flasher relay. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 8772 Hazard Flasher Relay: Diagrams EMERGENCY FLASHER RELAYS #1 and #2 (POLICE OPTION) Emergency Flasher Relays #1 and #2 (Police Option) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 8773 Hazard Flasher Relay: Testing and Inspection EMERGENCY FLASHER RELAYS #1 and #2 (POLICE OPTION) Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations REAR FLASHER (Police Option) Center rear of the luggage compartment. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8780 Hazard Warning Switch: Description and Operation Hazard Flasher Switch 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8781 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8782 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8783 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8784 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Removal Hazard Warning Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Removal > Page 8787 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Removal > Page 8788 Hazard Warning Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications Headlamp Bulb: Specifications Low Beam 4.3 A 55 W High Beam 5.08 A 65 W Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications > Page 8793 Headlamp Bulb: Service Precautions 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications > Page 8794 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8798 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8799 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8800 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8801 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal Headlamp Dimmer Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal > Page 8804 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal > Page 8805 Headlamp Dimmer Switch: Service and Repair Installation 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8809 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8810 Main Light Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8811 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8812 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8813 Main Light Switch: Service and Repair REMOVAL 1. Remove the instrument panel cluster finish panel. For additional information, refer to Dash Board. 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 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8818 Horn Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair NOTE: The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Air Bag Systems. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Locations Illuminated Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8827 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8828 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8829 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8830 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8831 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8832 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8833 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8834 Illuminated Entry 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8835 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8836 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8837 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8838 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8839 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8840 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8841 Illuminated Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8842 Illuminated Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 8843 Illuminated Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 8844 Illuminated Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 8845 Illuminated Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 8846 Illuminated Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8851 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8852 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8853 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8854 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8855 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8856 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8857 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8858 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8859 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8860 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8861 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8862 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8863 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8864 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8865 License Plate Lamp: Electrical Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 8866 License Plate Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking lamps; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Service and Repair Map Light: Service and Repair For Further information regarding the Service of this component and the system that it is a part of, please refer to Dome Lamp; Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8874 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8875 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8876 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8877 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8878 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8879 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8880 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8881 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8882 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8883 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8884 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8885 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8886 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8887 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8888 Marker Lamp: Electrical Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8889 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. 4. Remove the side marker lamp assembly. ^ Disconnect the electrical connector(s). ^ If necessary, install new bulb(s). Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8890 INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8897 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8898 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8899 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8900 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8901 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8902 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 Parking Lamp: Electrical Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8910 Parking Lamp: Description and Operation Lamps - Parking, Rear and Side Marker 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 AUTOLAMPS positions. License Lamps The license lamps have replaceable miniature bulbs and are provided power through the LCM and interconnected wiring with the headlamp switch in the PARK, HEAD, or AUTOLAMP positions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Parking 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 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 scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 5. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual. 6. Carry Out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESP/NOT EQUIP for lighting control module (LCM), go to Pinpoint Test A. See: Headlamp/Testing and Inspection/Headlamps/Pinpoint Tests/Test 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 (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8913 Parking Lamp: Diagnostic Trouble Code Descriptions Part 1 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8914 Part 2 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8915 Part 3 Of 3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8916 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8917 Parking Lamp: Pinpoint Tests V1 - V3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8918 V4 W1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8919 W2 - W4 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8920 X1 - X3 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8921 Y1 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8922 Parking Lamp: Scan Tool Testing and Procedures Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8923 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Page 8924 Special Tools Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 DRL Module Bolt 3 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8929 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8930 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 8931 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)Daytime Running Lamps or more to learn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8940 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8941 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8947 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8948 13C788 42 OASIS CODES: 201000, 201100, 201200, 206000 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8954 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8955 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8956 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8957 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8958 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8964 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8965 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8966 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8967 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 8968 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Page 8969 Exterior Lighting Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Exterior 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8972 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8973 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8974 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8975 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8976 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8977 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8978 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8979 Exterior 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8980 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8981 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8982 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8983 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8984 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8985 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8986 Exterior Lighting Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8987 Exterior Lighting Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8988 Exterior Lighting Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8989 Exterior Lighting Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8990 Exterior Lighting Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Diagrams > Page 8991 Exterior Lighting Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch Hazard Flasher Relay: Locations Maltifunction Switch Hazard Flasher Relay is replaced by the Multifunction switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8996 View 151-6 Multifunction Switch Locations See: Hazard Warning Lamps/Hazard Warning Switch Description and Operation Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8997 Connector View See: Diagrams Diagrams by Numbers, Diagram Set 90 Electrical Diagram Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8998 Hazard Flasher Relay: Locations Emergency Flasher Relays #1 and #2 (Police Option) Left hand rear of the luggage compartment, inside the emergency flasher relay block. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Maltifunction Switch > Page 8999 Hazard Flasher Relay: Locations Rear Flasher Relay (Police Option) Center rear of the luggage compartment, on rear flasher relay. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 9000 Hazard Flasher Relay: Diagrams EMERGENCY FLASHER RELAYS #1 and #2 (POLICE OPTION) Emergency Flasher Relays #1 and #2 (Police Option) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 9001 Hazard Flasher Relay: Testing and Inspection EMERGENCY FLASHER RELAYS #1 and #2 (POLICE OPTION) Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 9005 Horn Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Locations Illuminated Entry Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9011 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9012 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9013 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9014 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9015 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9016 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9017 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9018 Illuminated Entry 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9019 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9020 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9021 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9022 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9023 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9024 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9025 Illuminated Entry Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9026 Illuminated Entry Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 9027 Illuminated Entry Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 9028 Illuminated Entry Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 9029 Illuminated Entry Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 9030 Illuminated Entry Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 9035 Ambient Light Sensor: Service Precautions CAUTION: To avoid damaging the light sensor amplifier electrical connector, carefully tilt the panel to expose the connector without stretching the wiring. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 9036 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Position 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Position Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9048 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Position 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Position Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9054 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9055 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9056 Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9057 Brake Pedal Position 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 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Testing and Inspection Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Testing and Inspection > Page 9061 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 9065 Hazard Warning Switch: Description and Operation Hazard Flasher Switch 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 9066 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 9067 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 9068 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 9069 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Removal Hazard Warning Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Removal > Page 9072 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Removal > Page 9073 Hazard Warning Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9077 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9078 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9079 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9080 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal Headlamp Dimmer Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal > Page 9083 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Removal > Page 9084 Headlamp Dimmer Switch: Service and Repair Installation 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9088 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. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9089 Main Light Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9090 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9091 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9092 Main Light Switch: Service and Repair REMOVAL 1. Remove the instrument panel cluster finish panel. For additional information, refer to Dash Board. 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 mi) or more to relearn the strategy. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair NOTE: The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Air Bag Systems. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 9099 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 9100 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 9101 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 9102 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Removal Turn Signal Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Removal > Page 9105 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Removal > Page 9106 Turn Signal Switch: Service and Repair Installation 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear Lamp Nuts 5 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9126 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9127 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9128 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9129 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9130 Tail Lamp: Electrical Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 9131 Tail Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 9132 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Testing and Inspection Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Testing and Inspection > Page 9137 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 9141 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 9142 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 9143 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 9144 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Removal Turn Signal Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Removal > Page 9147 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Removal > Page 9148 Turn Signal Switch: Service and Repair Installation 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Locations Heated Glass Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions Heated Glass 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9167 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9168 Heated Glass 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9169 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9170 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9171 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9172 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9173 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9174 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9175 Heated Glass Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9176 Heated Glass Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Page 9177 Heated Glass Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Page 9178 Heated Glass Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Page 9179 Heated Glass Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Page 9180 Heated Glass Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9184 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9185 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9193 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9194 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9195 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9196 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 9197 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Locations Heated Glass Control Module: Locations For further information regarding this component please refer to Multifunction Electronic Control Module; Locations. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions Heated Glass 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9205 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9206 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9211 Heated Glass 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9212 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9213 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9214 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9215 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9216 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9217 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9218 Heated Glass Control Module: Connector Views For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9219 Heated Glass Control Module: Electrical Diagrams For further information regarding this component please refer to Multifunction Electronic Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 9220 Heated Glass Control Module: Service Precautions For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 9221 Heated Glass Control Module: Description and Operation For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 9222 Heated Glass Control Module: Testing and Inspection For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 9223 Heated Glass Control Module: Service and Repair For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9227 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9228 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Driver Door Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Driver Door Module > Page 9233 Power Window Control Module: Locations One Touch Window Down Module In the center of the left hand front door, near the master window/door lock control switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9236 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9237 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9238 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9239 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9240 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9241 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9242 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9243 Power Window 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9244 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9245 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9246 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9247 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9248 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9249 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9250 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9251 Power Window Control Module: Electrical Diagrams DRIVER DOOR MODULE For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 9252 Power Window Control Module: Service Precautions DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 9253 Power Window Control Module: Description and Operation DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 9254 Power Window Control Module: Testing and Inspection DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 9255 Power Window Control Module: Service and Repair DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions Power Window Relay: 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9260 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9261 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9263 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9264 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9265 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9266 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9267 Power Window Relay: 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9268 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9269 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9283 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9284 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9285 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) 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 9288 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9289 Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9290 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9291 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9292 Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9293 Schematic Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9294 Power Window Switch: Testing and Inspection RR Window Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 9295 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 9296 Power Window Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Driver Door Module Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Driver Door Module > Page 9302 Power Window Control Module: Locations One Touch Window Down Module In the center of the left hand front door, near the master window/door lock control switch. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Power Window 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9314 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9315 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9316 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9317 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9318 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9319 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9320 Power Window Control Module: Electrical Diagrams DRIVER DOOR MODULE For further information regarding this component please refer to Power Door Lock Control Module; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 9321 Power Window Control Module: Service Precautions DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service Precautions. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 9322 Power Window Control Module: Description and Operation DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Description and Operation. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 9323 Power Window Control Module: Testing and Inspection DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 9324 Power Window Control Module: Service and Repair DRIVER DOOR MODULE For further information regarding this component please refer to Multifunction Electronic Control Modules (General Module); Service and Repair. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications Front Door Window Motor: Specifications No Load................................................................................................................................................ ....................................5 amperes or less at 12.8 volts Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 9329 Front Door Window Motor: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 9330 Front Door Window Motor: Service and Repair 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. For additional information, refer to Battery. 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 9331 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications Rear Door Window Motor: Specifications No Load................................................................................................................................................ ....................................5 amperes or less at 12.8 volts Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 9335 Rear Door Window Motor: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 9336 Rear Door Window Motor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 9337 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions Power Window Relay: 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9342 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9343 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 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. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 Power Window Relay: 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9361 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9362 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9363 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9366 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9367 Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9368 Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9369 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9370 Power Window Switch: Testing and Inspection RF Window/Door Lock Control Switch Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9371 Schematic Terminals Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9372 Power Window Switch: Testing and Inspection RR Window Control Switch Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > LR Window Control Switch > Page 9373 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 9374 Power Window Switch: Service and Repair 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair Window Frame: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior weatherstrip. 3. Remove the front door window glass. For additional information, refer to Window Glass - Front Door. 4. Remove the interior garnish moulding. 5. Remove the bolt. 6. Remove the exterior weatherstrip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Page 9378 7. Remove the door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING GLASS FROM THE VEHICLE. 1. Remove the package tray trim panel. 2. Disconnect the back window glass electrical connectors. 3. Using a soft brush or vacuum, clean any dirt or foreign material from the pinch weld. 4. Using the special tool, starting at the top center of the back window glass cut the sealant from the glass and work down the sides. CAUTION: Care must be taken to prevent scratching the pinch weld. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9383 NOTE: Lubricate the existing sealant with water to aid the special tool while cutting. 5. Using the special tool, distance the back window glass from the body. 6. Using the special tool, cut the remaining sealant and remove the back window glass INSTALLATION CAUTION: After installing the urethane installed back window glass, the vehicle should not be driven until the urethane sealant has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane sealant may adversely affect the strength of the urethane sealant bond. 1. Dry-fit the back window glass by centering it side-to-side and by adjusting the blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body. 2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld. CAUTION: Care must be taken to avoid scratching the pinch weld. 3. Using a wool applicator, apply the Urethane Metal Primer Essex U-413 meeting Ford specification WAB-M234-C to any exposed metal on the pinch weld and allow six to ten minutes to dry. 4. If reinstalling the original back window glass, remove any excess urethane sealant from the glass. 5. If installing a new back window glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean. 6. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the class surface to be prepped. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9384 CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area. 7. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was in the previous step. Allow five minutes to dry. 8. Cut the applicator tip to specification. 9. Apply a bead of Urethane Sealant Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld. CAUTION: If the vehicle is to be driven within 24 hours of urethane sealant application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time. 10. Using the alignment marks install the back window glass. CAUTION: Open a windows to prevent the back window glass from being pushed out by air pressure when the door is closed. 11. After the glass is set, check for water leaks and add urethane sealant where needed. 12. Connect the back window glass electrical connectors. 13. Install the package tray trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments Front Door Window Glass: Adjustments 1. Remove the front door trim panel. 2. Partially lower the front door window glass. 3. Loosen the top regulator nuts. 4. Fully raise the door window glass. 5. Tighten the nuts. 6. Cycle the window regulator fully to verify normal operation. 7. Install the front door trim panel. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments > Page 9388 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 Remove the pull strap handle. 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 VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments > Page 9389 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 Nm(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 VIN W (2000)) 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 weatherstrip. 5. Remove the rear door window glass. For additional information, refer to Window Glass - Rear Door. 6. Remove the rear door window garnish moulding. 7. Remove the nut and the exterior weatherstrip. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 9393 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 VIN W (2000)) 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. 6. Remove the bolt. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 9397 7. Remove the rear door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) 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 Remove the pull strap handle. 3. Remove the front door window glass. For additional information, refer to Window Glass - Front Door. 4. Disconnect the connector. 5. Remove the rivets. 6. Remove the Torx(R) screws. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 9402 7. Remove the nuts. 8. Remove the regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair 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. For additional information, refer to Window Glass - Rear Door. 5. Disconnect the connector. 6. Remove the rivets. 7. Remove the nuts. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 9406 8. Remove the rear door window regulator. INSTALLATION 1. To install, reverse the removal procedure. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 9411 Windshield: Vehicle Damage Warnings CAUTION: ^ Care must be taken to avoid scratching the pinch weld. ^ After installing the urethane installed windshield glass, the vehicle should not be driven until the urethane sealant has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane sealant may adversely affect the strength of the urethane sealant bond. ^ Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area. ^ If the vehicle is to be driven within 24 hours of urethane sealant application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time. ^ Open a window to prevent the windshield glass from being pushed out by air pressure when a door is closed. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9412 Windshield: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the windshield wiper pivot arms. 2. Remove the cowl grille. 3. Remove the sun visors and clips. 4. Remove the windshield side garnish mouldings. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9413 5. Remove the instrument panel defroster opening grille. ^ If equipped, disconnect the electrical connectors. 6. Remove the interior rear view mirror. For additional information, refer to Mirrors 7. Lower the front portion of the headliner. 8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. 9. Using the special tool, starting at the top center of the windshield glass cut the urethane sealant from the glass and work down the sides. CAUTION: Care must be taken to prevent scratching the pinch weld. NOTE: Lubricate the existing urethane sealant with water to aid the special tool while cutting. 10. Using the special tool, distance the windshield glass from the body. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9414 11. Using the special tool cut the remaining sealant and remove the windshield glass 12. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed windshield glass, the vehicle should not be driven until the urethane sealant has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane sealant may adversely affect the strength of the urethane sealant bond. 1. Dry-fit the windshield glass by centering it side-to-side and by adjusting the blocks (if equipped) to get the correct position of the part top-to-bottom. Make alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body. 2. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane is removed leaving a level bead around the entire pinch weld. CAUTION: Care must be taken to avoid scratching the pinch weld. 3. Using a wool applicator, apply the Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M234-C to any exposed metal on the pinch weld and allow six to ten minutes to dry. 4. If reinstalling the original windshield glass, remove any excess urethane sealant from the glass. 5. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean. 6. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area. 7. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was in the previous step. Allow five minutes to dry. 8. Cut the applicator tip to specification. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9415 9. Apply a bead of Urethane Sealant Essex 400-HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld. CAUTION: If the vehicle is to be driven within 24 hours of urethane sealant application, Urethane Sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time. 10. Using the alignment marks install the windshield glass. CAUTION: Open a window to prevent the windshield glass from being pushed out by air pressure when a door is closed. 11. After the glass is set, check for water and air leaks through the urethane sealant and add urethane sealant where needed. 12. Install the front portion of the headliner. 13. Install the interior rear view mirror. For additional information, refer to Mirrors 14. Install the instrument panel defroster opening grille assembly. ^ If equipped, connect the electrical connectors. 15. Install the windshield side garnish mouldings. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9416 16. Install the sun visors and clips. 17. Install the cowl grille. 18. Adjust the windshield wiper pivot arms. For additional information, refer to Wiper and Washer Systems. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 9417 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > NHTSA00V138000 > Dec > 00 > Recall 00V138000: Wiper Control Module Replacement Wiper Control Module: Recalls Recall 00V138000: Wiper Control Module Replacement Vehicle Description: A windshield wiper control module may not be capable of carrying the current required during high load conditions on the wipers (i.e., ice, snow, or other debris). This condition could result in inoperative wipers with no advance warning. Dealers will inspect the wiper control modules and replace if necessary. Owner notification began May 19, 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 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). 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement Technical Service Bulletin # 00S09 Date: 000501 Recall - Wiper Control Module Replacement 00S09 SAFETY RECALL DEMONSTRATION/DELIVERY HOLD - Certain 2000 Model Year Crown Victoria and Grand Marquis - Windshield Wiper Control Module Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9432 Attachment I - Administrative Information OASIS OASIS will be activated for this recall Tuesday May 9, 2000. 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9433 ^ 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 cars are not authorized for this recall. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Seed Stocking of the wiper control modules will begin the week of May 15, 2000 and will continue for the next several weeks until 75% of each dealer's "Affected Unit Volume" has been shipped. The first seed stock shipment will be sent as an Interim Order. All other seed stock orders will be sent with your weekly Stock Order. After June 16, 2000, dealers should order parts through normal order processing channels. Service part orders for this wiper control module on vehicles not affected by this recall must be ordered through the Recall Hotline at 1-800-325-5621 until June 16, 2000. There are approximately 23,000 total vehicles involved in this recall. ORDER INFORMATION DOR/COR DOR/COR number 50160 identifies parts ordered for this campaign through the following: ^ Seed Stock Program ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9434 Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module location and replacement instructions. INSPECTION PROCEDURE The module must first be inspected for a green dot to determine if replacement is required. Modules that have a green dot have been updated at the assembly plant and do NOT require replacement. 1. Open the ashtray and look between the dash panel and the ashtray at the visible face of the wiper control module. 2. Inspect the module for a green dot (sticker). If necessary, shine a flashlight from under the dash panel to illuminate the module. If the module has a green dot, do not replace the module and return the vehicle to the customer. Replace the module if there is no green dot. MODULE REPLACEMENT PROCEDURE Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module replacement instructions. Bracket Transfer The module bracket must be transferred from the old module to the new module.The bracket is held in place by two round retaining buttons; depress the buttons simultaneously and slide the bracket off the old module. The bracket will lock into place automatically when it is slid onto the new module. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9435 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9436 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > NHTSA00V138000 > Dec > 00 > Recall 00V138000: Wiper Control Module Replacement Wiper Control Module: All Technical Service Bulletins Recall 00V138000: Wiper Control Module Replacement Vehicle Description: A windshield wiper control module may not be capable of carrying the current required during high load conditions on the wipers (i.e., ice, snow, or other debris). This condition could result in inoperative wipers with no advance warning. Dealers will inspect the wiper control modules and replace if necessary. Owner notification began May 19, 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 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). 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement Technical Service Bulletin # 00S09 Date: 000501 Recall - Wiper Control Module Replacement 00S09 SAFETY RECALL DEMONSTRATION/DELIVERY HOLD - Certain 2000 Model Year Crown Victoria and Grand Marquis - Windshield Wiper Control Module Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9446 Attachment I - Administrative Information OASIS OASIS will be activated for this recall Tuesday May 9, 2000. 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9447 ^ 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 cars are not authorized for this recall. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Seed Stocking of the wiper control modules will begin the week of May 15, 2000 and will continue for the next several weeks until 75% of each dealer's "Affected Unit Volume" has been shipped. The first seed stock shipment will be sent as an Interim Order. All other seed stock orders will be sent with your weekly Stock Order. After June 16, 2000, dealers should order parts through normal order processing channels. Service part orders for this wiper control module on vehicles not affected by this recall must be ordered through the Recall Hotline at 1-800-325-5621 until June 16, 2000. There are approximately 23,000 total vehicles involved in this recall. ORDER INFORMATION DOR/COR DOR/COR number 50160 identifies parts ordered for this campaign through the following: ^ Seed Stock Program ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9448 Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module location and replacement instructions. INSPECTION PROCEDURE The module must first be inspected for a green dot to determine if replacement is required. Modules that have a green dot have been updated at the assembly plant and do NOT require replacement. 1. Open the ashtray and look between the dash panel and the ashtray at the visible face of the wiper control module. 2. Inspect the module for a green dot (sticker). If necessary, shine a flashlight from under the dash panel to illuminate the module. If the module has a green dot, do not replace the module and return the vehicle to the customer. Replace the module if there is no green dot. MODULE REPLACEMENT PROCEDURE Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module replacement instructions. Bracket Transfer The module bracket must be transferred from the old module to the new module.The bracket is held in place by two round retaining buttons; depress the buttons simultaneously and slide the bracket off the old module. The bracket will lock into place automatically when it is slid onto the new module. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9449 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9450 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9451 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9452 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9453 Wiper Control Module: Service Precautions CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9454 Wiper Control Module: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9455 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9456 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9461 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9462 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9463 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9464 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal Windshield Washer Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal > Page 9467 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal > Page 9468 Windshield Washer Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9472 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9473 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9474 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9475 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal Wiper Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 9478 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 9479 Wiper Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions Windshield Washer Pump: Service Precautions WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON LABEL OF WASHER SOLUTION CONTAINER. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 9483 Windshield Washer Pump: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 9484 Windshield Washer Pump: Service and Repair REMOVAL 1. Remove the air cleaner assembly; refer to Fuel Delivery and Air Induction. 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions Windshield Washer Reservoir: Service Precautions WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON LABEL OF WASHER SOLUTION CONTAINER. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Page 9488 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Remove the air cleaner assembly; refer to Fuel Delivery and Air Induction. 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9492 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9493 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9494 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9495 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal Windshield Washer Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal > Page 9498 1 Remove the screws. 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Removal > Page 9499 Windshield Washer Switch: Service and Repair Installation 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications LH wiper pivot arm installation position .......................................................................................................................................... 2-26 mm (.07-1.02 inch) RH wiper pivot arm installation position ......................................................................................................................................... 5-33 mm (.19-1.29 inch) Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 9503 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 9504 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > NHTSA00V138000 > Dec > 00 > Recall 00V138000: Wiper Control Module Replacement Wiper Control Module: Recalls Recall 00V138000: Wiper Control Module Replacement Vehicle Description: A windshield wiper control module may not be capable of carrying the current required during high load conditions on the wipers (i.e., ice, snow, or other debris). This condition could result in inoperative wipers with no advance warning. Dealers will inspect the wiper control modules and replace if necessary. Owner notification began May 19, 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 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). 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement Technical Service Bulletin # 00S09 Date: 000501 Recall - Wiper Control Module Replacement 00S09 SAFETY RECALL DEMONSTRATION/DELIVERY HOLD - Certain 2000 Model Year Crown Victoria and Grand Marquis - Windshield Wiper Control Module Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9520 Attachment I - Administrative Information OASIS OASIS will be activated for this recall Tuesday May 9, 2000. 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9521 ^ 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 cars are not authorized for this recall. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Seed Stocking of the wiper control modules will begin the week of May 15, 2000 and will continue for the next several weeks until 75% of each dealer's "Affected Unit Volume" has been shipped. The first seed stock shipment will be sent as an Interim Order. All other seed stock orders will be sent with your weekly Stock Order. After June 16, 2000, dealers should order parts through normal order processing channels. Service part orders for this wiper control module on vehicles not affected by this recall must be ordered through the Recall Hotline at 1-800-325-5621 until June 16, 2000. There are approximately 23,000 total vehicles involved in this recall. ORDER INFORMATION DOR/COR DOR/COR number 50160 identifies parts ordered for this campaign through the following: ^ Seed Stock Program ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9522 Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module location and replacement instructions. INSPECTION PROCEDURE The module must first be inspected for a green dot to determine if replacement is required. Modules that have a green dot have been updated at the assembly plant and do NOT require replacement. 1. Open the ashtray and look between the dash panel and the ashtray at the visible face of the wiper control module. 2. Inspect the module for a green dot (sticker). If necessary, shine a flashlight from under the dash panel to illuminate the module. If the module has a green dot, do not replace the module and return the vehicle to the customer. Replace the module if there is no green dot. MODULE REPLACEMENT PROCEDURE Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module replacement instructions. Bracket Transfer The module bracket must be transferred from the old module to the new module.The bracket is held in place by two round retaining buttons; depress the buttons simultaneously and slide the bracket off the old module. The bracket will lock into place automatically when it is slid onto the new module. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9523 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Recalls for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9524 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > NHTSA00V138000 > Dec > 00 > Recall 00V138000: Wiper Control Module Replacement Wiper Control Module: All Technical Service Bulletins Recall 00V138000: Wiper Control Module Replacement Vehicle Description: A windshield wiper control module may not be capable of carrying the current required during high load conditions on the wipers (i.e., ice, snow, or other debris). This condition could result in inoperative wipers with no advance warning. Dealers will inspect the wiper control modules and replace if necessary. Owner notification began May 19, 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 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). 2000 FORD CROWN VICTORIA 2000 MERCURY GRAND MARQUIS Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement Technical Service Bulletin # 00S09 Date: 000501 Recall - Wiper Control Module Replacement 00S09 SAFETY RECALL DEMONSTRATION/DELIVERY HOLD - Certain 2000 Model Year Crown Victoria and Grand Marquis - Windshield Wiper Control Module Replacement ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9534 Attachment I - Administrative Information OASIS OASIS will be activated for this recall Tuesday May 9, 2000. 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 $1,100 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. 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: Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9535 ^ 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 cars are not authorized for this recall. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Seed Stocking of the wiper control modules will begin the week of May 15, 2000 and will continue for the next several weeks until 75% of each dealer's "Affected Unit Volume" has been shipped. The first seed stock shipment will be sent as an Interim Order. All other seed stock orders will be sent with your weekly Stock Order. After June 16, 2000, dealers should order parts through normal order processing channels. Service part orders for this wiper control module on vehicles not affected by this recall must be ordered through the Recall Hotline at 1-800-325-5621 until June 16, 2000. There are approximately 23,000 total vehicles involved in this recall. ORDER INFORMATION DOR/COR DOR/COR number 50160 identifies parts ordered for this campaign through the following: ^ Seed Stock Program ^ 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 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9536 Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module location and replacement instructions. INSPECTION PROCEDURE The module must first be inspected for a green dot to determine if replacement is required. Modules that have a green dot have been updated at the assembly plant and do NOT require replacement. 1. Open the ashtray and look between the dash panel and the ashtray at the visible face of the wiper control module. 2. Inspect the module for a green dot (sticker). If necessary, shine a flashlight from under the dash panel to illuminate the module. If the module has a green dot, do not replace the module and return the vehicle to the customer. Replace the module if there is no green dot. MODULE REPLACEMENT PROCEDURE Refer to the 2000 Crown Victoria and Grand Marquis workshop manual Group 5 Section 501 for wiper control module replacement instructions. Bracket Transfer The module bracket must be transferred from the old module to the new module.The bracket is held in place by two round retaining buttons; depress the buttons simultaneously and slide the bracket off the old module. The bracket will lock into place automatically when it is slid onto the new module. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9537 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Control Module: > 00S09 > May > 00 > Recall - Wiper Control Module Replacement > Page 9538 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9539 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9540 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9541 Wiper Control Module: Service Precautions CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9542 Wiper Control Module: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9543 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Page 9544 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9549 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9550 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9551 Wiper Motor: Specifications Windshield Wiper Motor Bolts 10 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9552 Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9553 Wiper Motor: Service Precautions 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9554 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9555 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 VIN W (2000)) 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9560 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 9561 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 9562 Wiper Motor Linkage: Specifications Mounting Arm and Pivot Shaft Bolts 12 Nm Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 9563 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 9564 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 VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams For further information regarding this component please refer to Lighting and Horns; Diagrams. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9568 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9569 Component Testing Procedure Terminals Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9570 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9571 Schematic Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal Wiper Switch: Service and Repair Removal Multifunction Switch 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. Ford Crown Victoria Workshop Manual (V8-4.6L VIN W (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Removal > Page 9574 1 Remove the screws. 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.