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FORD HIGH PRESSURE SYSTEM DIAGNOSTICS REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 16-04-2012

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SERVICE PROCEDURE IT IS NOT NECESSARY TO REPLACE THE HIGH PRESSURE PUMP WHEN REPLACING THE A minimum of 3.5 MPa (500 psi or 0.8 volts) ICP is QUICK CONNECT FITTINGS. required before the injectors are enabled. No or low oil in the system, leakage at the injector upper 4. If a leak is identified in the branch tube, use D-rings, high pressure pump quick connect fitting, the following procedure to replace the branch high pressure pump discharge tube, faulty injection tube if the vehicle your working on is a F-Super pressure regulator (IPR), high pressure pump, or Duty or Excursion. For E-Series, the engine branch tube could cause low ICP pressure. needs to be removed to replace the branch tube. When replacing the branch tube, also 1. Perform the revised Powertrain Controls / install the STC bracket kit. Emissions Diagnosis (PC/ED) lead diagnostics Section 4, Hard Start / No Start Diagnostic BRANCH TUBE REPLACEMENT FOR F-SUPER Procedure Tests 10e and 10f. These tests were DUTY AND EXCURSION VEHICLES ONLY revised in January 2006. 1. Remove the transmission. See the appropriate NOTE model year Workshop Manual (WSM), Section 307-01. THE LOW PRESSURE OIL SYSTEM MUST BE WORKING PROPERLY IN ORDER FOR THE HIGH NOTE PRESSURE OIL SYSTEM TO BUILD ICP LEAVE THE FLYWHEEL ON THE ENGINE, AS IT PRESSURE. THIS INCLUDES ADEQUATE WILL MAKE IT EASIER TO TURN THE ENGINE PRESSURE AND GOOD QUALITY PROPERLY OVER TO TOP DEAD CENTER (TDC) AND THE MAINTAINED OIL. TRANSMISSION FLUID DOES NOT NEED TO BE NOTE DRAINED. THIS TSB ONLY APPLIES TO REPLACEMENT OF 2. Set engine at TDC both cylinder number 1 ANY COMPONENT FOUND DEFECTIVE WHILE rocker arms should be loose. See rocker arm PERFORMING PC/ED HARD START / NO START removal procedure in the appropriate online TESTS 10e AND 10f. WSM, Section 303-01C

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1995-1997 FORD EXPLORER TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP

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Filed Under (Ford Manuals) by admin on 20-01-2012

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TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP ISSUE to the Data Link Connector (DLC) underneath The diagnostic procedure for binding or shudder the steering wheel. Monitor for any Diagnostic from transfer case in slow, tight turns while in 4 Trouble Codes (DTCs) set by the transfer case Auto mode may be inaccurate for some vehicles. that could indicate incorrect speed sensor function. Codes could include, but are not ACTION limited to: Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure. •P1836 – Front propshaft sensor circuit failure •P1837 – Rear propshaft sensor circuit failure DIAGNOSTIC PROCEDURE •P1874 – Hall effect sensor power short circuit to battery 1997 EXPLORER •P1875 – Hall effect sensor power circuit 1. Test drive the vehicle in 4 Auto, 4 High and 4 failure Low. Evaluate the vehicle in each of these NOTE modes. The vehicle should bind in turns in both ADDITIONAL CODES COULD BE SET AS WELL. 4 High and 4 Low, but not in 4 Auto. The 4 PLEASE REFER TO THE APPROPRIATE YEAR High mode is intended for severe winter EXPLORER SERVICE MANUAL FOR COMPLETE weather or off-road driving only. It is not LISTING AND EXPLANATION. intended for use on dry or merely wet pavement. 3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and 2. Verify the instrument panel has the proper 4X4 replace accordingly. Drive the vehicle to verify if selection label (Figure 1). Proceed to 1995-97 the shudder/binding has been eliminated. Send Explorer heading, Step 1. replaced speed sensor to the Ford Warranty 1995-97 EXPLORER Parts Return Center, Canton, MI. NOTE 4. Using NGS Tester, monitor the Parameter 4 AUTO IS THE FAR LEFT SWITCH POSITION Identification Display (PID) on the transfer case ON 1997 MODELS AND IS THE MIDDLE clutch duty cycle. If the 4 Auto mode reads POSITION ON 1996 MODELS. something higher than one (1), verify speed sensors have not set any Generic Electronic 1. If during test driving, the vehicle shudders or Module (GEM) DTCs and follow the speed binds in 4 Auto during slow forward or reverse sensor diagnostic procedure in the above Step parking lot maneuvers, proceed to Step 2. 2. Verify the following while checking PID: Mode Duty Cycle Indicator 4 Auto 0 or 1 4 High 13 4 Low 38 at 5 MPH 5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil

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2001-2003 RAV4 HARSH SHIFT AND/ ORM.I.L. “ON”DTC P0750, P0755, P0758, AND/ ORP1760 REPAIR MANUAL

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Filed Under (Toyota Manuals) by admin on 10-02-2012

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HARSH SHIFT AND/ORM.I.L. “ON”DTCP 0750, P0755, P0758, AND/ORP1760 –TC 002-06 Revised March3,2006 Page 2of3 PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 89661–42650 1 89661–42651 89661–42653 1 89661–42652 1 89661–42660 1 89661–42661 89661–42663 Engine Control Module (ECM) 1 89661–42662 Engine Control Module (ECM) 1 89661–42810 89661–42811 1 89661–42820 89661–42821 1 89661–42880 Same 1 89661–42890 Same 1 ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTYDRW** 1 Toyota Diagnostic Tester Kit* NOTE: SAll components from this kit/set are required S12 MegabyteDiagnostic Tester Program Card (P/N 01002593–005) with version 13.3aSoftware (or later) is required TOY220036 1 9 *Essential SSTs. **Referstodrawer number in SST Storage System. NOTE: Additional Diagnostic Tester Kits, Program Cards, or other SST smaybeorderedby callingSPX/OTC at 1-800-933-8335. 1. If the vehicle is currently exhibiting a harsh shift condition and/or M.I.L. “ON”with DTCP0750, P0753, P0755, P0758, and/or P1760 stored, refer to the Technical Information System (TIS), 2001–2003 model year RAV4 Repair Manual: S4WD: Diagnostics/Automatic Transaxle (U140f): Problem Symptoms Table S2WD: Diagnostics/Automatic Transaxle (U142E): Problem Symptoms Table NOTE: In some instances the vehicle must be operated at least 30 minutes before the condition can be duplicated. 2. If the vehicle exhibits the above condition, replace the ECM (PCM). Parts Information Required SSTs

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2009 Ford Escape 3.0L INTERMITTENT CYLINDER HEAD CAMSHAFT KNOCK/ THUMP NOISE SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 25-01-2012

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3.0L INTERMITTENT CYLINDER HEAD CAMSHAFT KNOCK/THUMP NOISE This article supersedes TSB 09-11-6 to update the b. Isolate noise to LH – Listen to the cylinders Service Procedure and Part List. 4 and 6 valve cover fasteners (number 6 is by the coolant pump). There will be a ISSUE significant difference in transmitted noise Some 2009 Escape and Mariner vehicles, equipped between the cylinder 4 and 6 fasteners with 3.0L engine, may exhibit an intermittent when noise is present. Noise from LH – go knocking or thumping type noise from the cylinder to Step 4. head. After engine temperature reaches 210-220 °F NOTE (99-104 °C), the noise is typically heard from the THE RH AND LH NOISES HAVE DIFFERENT rear of the engine as the vehicle comes to a stop. CAUSES. FOLLOW ALL STEPS CAREFULLY FOR An example would be coming to a stop at the end PROPER DIAGNOSIS AND REPAIR. of a highway exit ramp. Noise will continue 45-60 seconds and then diminish. Noise will occur again 3. Replace the RH cylinder head per Workshop once engine reaches 210-220 °F (99-104 °C) and Manual (WSM), Section 303-01B. vehicle comes to another stop. a. Verify repair by repeating Step 2. If noise is ACTION still present then proceed with normal Follow the Service Procedure steps to correct the engine NVH diagnostics per WSM, Section condition. 100-04. SERVICE PROCEDURE 4. Remove LH valve cover. Refer to WSM, Section 303-01. 1. Is noise a 45-60 second knock/thump from a hot engine as the vehicle comes to a stop? a. Rotate the engine clockwise until cylinder number 6 exhaust cam lobes are pointing a. Yes – Go to Step 2. up and valves are fully closed. Exhaust camshaft needs to be left in this position for b. No – Stop as this procedure does not apply. all bearing caps in Step 4b. (Figure 1) Proceed with normal Workshop Manual (WSM), Section 100-04 diagnostics. 2. Using Chassis Ears, isolate the noise to Right Hand (RH) (Bank 1) or Left Hand (LH) (Bank 2) cylinder head. Noise is typically heard as 45-60 second knock/thump as the vehicle comes to a stop after engine reaches 210-220 °F (99-104 °C). a. Isolate noise to RH – Listen to the cylinder head by the variable camshaft timing (VCT) solenoid connectors. There will also be a vibration felt at the VCT solenoid connector when noise is present. Noise from RH – go to Step 3.

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2004 Chevrolet Monte Carlo SS SCHEMATIC AND ROUTING DIAGRAMS THEFT DETERRENT SYSTEM SCHEMATICS

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Filed Under (Chevrolet Manuals) by admin on 29-05-2011

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DIAGNOSTIC SYSTEM CHECK – THEFT DETERRENT Test Description The number(s) below refer to the step number(s) on the diagnostic table. 2: Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5: The presence of DTCs which begin with “U” indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. 6: The listed DTCs are internal module malfunctions and should be corrected before attempting any other diagnostics. 7: The listed DTCs are battery voltage related malfunctions and should be corrected before attempting any other diagnostics. Diagnostic System Check – Theft Deterrent Step Action Yes No 1 Install a scan tool. Does the scan tool power up? Go to Step 2 Go to Scan Tool Does Not Power Up in Data Link Communications 2 1. Turn ON the ignition, with the engine OFF. 2. Attempt to establish communication with the body control module (BCM) and the powertrain control module (PCM). Does the scan tool communicate with the specified modules? Go to Step 3 Go to Scan Tool Does Not Communicate with Class 2 Device in Data Link Communications 3 1. Access the Class 2 Power Mode parameter in the Diagnostic Circuit Check menu on the scan tool. IMPORTANT: Important: The engine may start during the following step. Turn OFF the engine as soon as you have observed the Crank power mode. IMPORTANT: Insure that all ignition switch positions are observed

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2003-2005 FORD Excursion 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE MANUAL

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Filed Under (Ford Manuals) by admin on 17-11-2011

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For F-Super Duty, Excursions, and E-Series Once each of the tests are complete, use the IDS vehicles built on or after 9/30/2003, install the VPS help icon on the right side of the screen in each tool 418-626 along with IDS/VMM. The 418-626 test to help analyze the results. If the turbo fails was shipped in kit TKIT-2007VP-F and and leads to turbocharger replacement, continue TKIT-2007TV-F. Dealers should have received one with the Turbocharging Inspection Procedure to or the other of these two kits. check for internal turbocharger oil leakage and to determine if the turbocharger can be repaired with a To Install VPS CHRA replacement, or if it can be cleaned, instead of replacing the entire turbocharger. 1. Remove the threaded pipe plug from center housing of turbo. If the turbocharger passes the turbo tests, do not continue with this TSB. Follow the online KA pin 2. Remove the oil supply flange bolt closest to the point test found on the Professional Technician turbo label. Society (PTS) website and continue air 3. Drop in the VPS and secure with provided management diagnosis without replacing the clamp flat side up. turbocharger. 4. Torque the oil supply line bolt 7 lb-ft (10 N•m). NOTE VEHICLE PERFORMANCE ISSUES RELATED TO 5. The gasket is reusable and need only be FUEL QUALITY, MAINTENANCE AND replaced if an oil leak is present after final AFTERMARKET MODIFICATIONS ARE NOT assembly. COVERED BY FORD MOTOR COMPANY WARRANTY. To run test, start new session in IDS with VPS/VMM connected to the vehicle. Then select the Turbocharger Inspection Procedure Toolbox-Powertrain-Air Management-Boost test and follow the IDS screen prompts, and then continue 1. Remove the turbocharger for inspection with VVT test. Both the boost and VVT test should following Workshop Manual, Section 303-04D: be run in order. Fuel Charging and Controls. 2. Inspect compressor and turbine wheel fins for damage. Replace the turbocharger if fins are damaged. If fins are damaged, inspect the air intake system for damage allowing dirt or contamination to bypass the air filter

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2008 Ford F-Super Duty LACKS POWER, LEAKS FLUID FROM EXHAUST PIPE, ABNORMAL TAILPIPE SEDIMENT, WHITE SMOKE, EXHAUST SMELL, AND MIL ON SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 02-02-2012

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ACTION To diagnose and correct the concern, refer to the following Service Procedure. SERVICE PROCEDURE NOTE DO NOT START ENGINE Evaluation, Inspections, And Checks 1. Retrieve KOEO diagnostic trouble codes (DTCs). 2. Check oil level. Remove and clean dipstick. Reinsert into dipstick tube only until dipstick handle reaches top of dipstick tube (Figure 1). NOTE FIGURE 1 DEMONSTRATES DIPSTICK Figure 1 – Article 07-8-9 POSITIONING FOR OVER-FULL CHECK. KEEP 3. Check coolant level. DIPSTICK HANDLE OFFSET OF CENTER TO PREVENT IT FROM FULLY SEATING. IF OIL 4. Check fuel quality. LEVEL IS BELOW THE MAX MARK, OIL IS NOT OVER-FULL. 5. Inspect tailpipes for abnormal sediment; for example black soot, white ash, oil, coolant, or fuel. 6. Inspect vehicle for coolant, oil and fuel leaks at the following locations: •Tailpipes Repair Directions •Section A – If the following DTCs are present P0087, P2291, P0263-0284, P0300-P0308, or P1336 or if observation of external fuel leaks, for example, wetness around exhaust manifolds or over-full oil level indication. •Section B – If the following DTCs are present P132B, P2262, or P2263 or observation of oil leaks (aside from over-full oil level) or oil level is low. Figure 2 – Article 07-8-9 •Section C – If coolant low or observation of 8. Replace any leaking components and verify coolant leaks. leak has been repaired while running IDS high •Sections A, B, and C – If only abnormal sediment pressure fuel system test – KOER. in tailpipes. 9. Perform WSM, Section 303-04D – Turbocharger SECTION – A Bearing Clearance Check. Fuel System Diagnostics 10. If fuel quality is poor, drain all fuel and replace with known good ultra-low sulfur diesel fuel. NOTE IN CASES WHERE ENGINE OIL HAS BEEN 11. If no DTCs were stored in pending or DILUTED WITH DIESEL FUEL AND ALL REPAIRS continuous memory go to Step 13. ARE COMPLETE, RELEASE THE OIL FILTER CAP 12. Is there abnormal sediment in tailpipes or fuel ALLOWING OIL TO DRAIN TO OIL PAN AND evident? KEEP FILTER, DRAIN THE OIL FROM OIL PAN AND FILL WITH NEW OIL. TIGHTEN OIL FILTER a. No – Complete PC/ED worksheet and CAP AND RUN ENGINE FOR 10 MINUTES. applicable PPT tests for the codes retrieved. FINALLY, CHANGE OIL FILTER AND OIL AGAIN. b. Yes – Go to Step 13. 1. If oil is not over-full – go to Step 9. 13. Is there abnormal sediment in the tailpipes?

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1993 Ford Crown Victoria V8-281 4.6L SOHC Engine – Lean Driveability Symptoms Manual

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Filed Under (Ford Manuals) by admin on 09-07-2012

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1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use “MAP/BARO” test under “Powertrain,” “Testers and Meters.” Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it’s 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics.

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1999 Mercury Sable V6-3.0L DOHC A/ T-Cooler Flushing Service Manual

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Filed Under (Mercury Manuals) by admin on 25-06-2012

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SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The “Turbo-Tank Heated Cooler Line Flusher” uses heated Automatic Transmission Fluid ( ATF ) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque- converters. There are 2 issues with this method: Aerosol Solvents should never be used for several reasons. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case . Refer to the following lists: Rear Wheel Drive ^Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. ^They do not provide the volume necessary to remove heavy contaminants. ^They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. ^TORQSHIFT, 4R100, E40D, C6 – The REAR transmission case filling receives the return line. ^4R70W, AODE, AOD – The TOP transmission case filling receives the return line. ^A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S The TOP transmission case filling receives the return line. ^CD4E – The REAR or Pump End transaxle case fitting receives the return line. ^4F27E – The REAR or Cover End transaxle case fitting receives the return line. ^AXOD, AXODE, AX4S, AX4N, 4F50N – The BOTTOM transaxle cooler line fitting receives the return line. 1. Check and top off fluid level of the “Turbo-Tank Heated Cooler Line Flusher” tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140°F (60°C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher’s blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher’s red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on “Turbo-Tank Heated Cooler Line Flusher”). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes

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2005 Ford F-Super Duty 250-550 Auxiliary Brake System/ Trailer Brake Control (TBC) Module Repair Manual

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Filed Under (Ford Manuals) by admin on 14-06-2012

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connected to the vehicle, the TBC module will enter a “sleep mode” but still continue to send a PWM voltage signal to the trailer tow connector every 4 seconds to detect when a trailer is connected. When the ignition key is in the RUN position and the module is in sleep mode, pressing a gain button or sliding the manual switch will cause the module to “wake up”. If a trailer is not connected to the vehicle, the display should prove out for 3 seconds, then the trailer icon should illuminate red and the IC message center should display TRAILER DISCONNECTED or CHECK TRAILER. If a trailer is connected to the vehicle, the display should prove out for 3 seconds and then the trailer icon should illuminate green. Inspection and Verification NOTE: A trailer brake emulator tool is available to verify that the TBC module and vehicle wiring are functioning correctly. 1. Verify the TBC system is correctly installed by checking that the vehicle is equipped with a brake pressure transducer on the master cylinder. If the brake pressure transducer is not present, then the TBC system has been erroneously installed. 2. Verify the customer concern. 3. NOTE: The TBC does not function with electric-over-hydraulic or surge trailer brake types. Verify that the trailer brakes are electric-actuated drum type brakes. 4. Verify the stoplamps operate correctly by applying and releasing the brake pedal with the ignition switch in the OFF position and the trailer disconnected. If the stoplamps do not operate correctly, refer to Section 417-01 . If the stoplamps operate correctly, proceed to the next step. 5. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 6. If the cause is not visually evident, connect the scan tool to the data link connector (DLC) 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. 7. If the scan tool still does not communicate with the vehicle, refer to the scan tool operating manual. 8. Carry out the scan tool data link test. If the scan tool responds with: * CAN, ISO, or UBP circuit fault; all electronic control units no response/not equipped, refer to Section 418-00 . * No response/not equipped for the TBC, GO to Pinpoint Test A . * System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the TBC and the antilock brake system (ABS) module. 9. If the DTCs retrieved are related to the concern, go to the Trailer Brake Control (TBC) module Diagnostic Trouble Code (DTC) Chart or Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Chart to continue diagnosis. 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnosis. NOTE: Always retrieve the continuous DTCs after running the self-test.

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