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2000 Ford Windstar INCORRECT FUEL GAUGE INDICATION Workshop Manual

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Filed Under (Ford Manuals) by admin on 12-05-2012

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The fuel gauge does not change indication unless there has been at least 3 gallons of fuel added or deleted between ignition switch cycle. Use recorded REM and instrument cluster DTCs from the Continuous and On- Demand self-test. ? Are any DTCs recorded? Yes If REM DTC B1201 or IC DTC U1131 is retrieved, GO to D6 . No GO to D2. D2 CARRY OUT THE ICM FUEL GAUGE ACTIVE COMMAND IC Active Command Select the IC FUEL GAUGE CONTROL active command. Trigger FUELLEVEL active command. Toggle and monitor the fuel gauge while adjusting the FUELLEVEL active command to read 50% and 100% Did the fuel gauge needle start at empty (E), move to half at 50%, and full (F) at 100%? Yes GO to D3. No INSTALL a new instrument cluster; REFER to Instrument Cluster. CLEAR the DTC. REPEAT the instrument cluster self-test. D3 CHECK THE FUEL GAUGE READING Fuel Pump Module C412 Connect one lead of Instrument Gauge System Tester to fuel pump module C412 Pin 5, Circuit 1357 (LB/YE), harness side. Connect the other lead to fuel pump module C412 Pin 8, Circuit 1356 (LG/VT), harness side. Set the power switch on Instrument Gauge System Tester to the ON position Set Instrument Gauge System Tester to 15 ohms. Wait one minute. Set Instrument Gauge System Tester to 160 ohms. Wait one minute. Read the fuel gauge. The fuel gauge should read full or above. Set Instrument Gauge System Tester to 15 ohms. Wait one minute. Read the fuel gauge. The fuel gauge should read empty or below Does the fuel gauge operate correctly? Yes GO to D4. No GO to D6. D4 INSPECT THE FUEL TANK Visually inspect the fuel tank for any damage or deformation. ? Is the fuel tank OK? Yes GO to D5. No INSTALL a new fuel tank. REFER to Section 310-01. TEST the system for normal operation. D5 INSPECT THE FUEL LEVEL SENSOR AND PUMP ASSEMBLY Visually inspect the fuel pump assembly for damaged wiring or connectors. Visually inspect the float and float rod for damage or obstruction

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Battery Electrical Drain/ Parasitic Load Test Repair Manual

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Filed Under (More Manuals) by admin on 29-05-2012

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1. Disconnect the battery negative cable 2. Install the male end of the J 38758 to the negative battery terminal. 3. Turn OFF the test switch. 4. Install the negative battery cable to the female end of the test switch. 5. Install the Scan Tool (or equivalent) or wait for 20 minutes. 6. Turn ON the test switch. 7. Road test the vehicle while activating all accessories, including the radio and the air conditioning. 8. Lower the door glass, then exit the vehicle. Do not move the door handle after closing the door. 9. Open the hood. Important The power down timer will reset to 20 minutes if any wake up inputs are received by a Class 2 device (after the scan tool has put all Class 2 devices to sleep). 10. Put all of the Class 2 devices into the sleep mode. 11. Turn OFF the ignition switch. Remove the key. Important From this point on, electrical continuity must be maintained in the ground circuit of the battery through the Test Switch J 38758 in the ON position or through the ammeter J 39200 . 12. Components such as PCM, VCM, Automatic Air Conditioning, and the Truck Body Control Module have timers that draw several amps of current while they cycle down. This can give a false parasitic drain reading. Wait 20 minutes for these components to power down before continuing this test (or use the scan tool to put all Class 2 devices to sleep). 13. Connect a jumper wire with a 10 A fuse J 36169-A to the terminals of the test switch. 14. Turn the test switch to the OFF position. 15. Wait ten seconds. If the fuse does not blow, the current is less than 10 A. The ammeter can be used safely. 16. Before the fused jumper wire is removed, turn the test switch to the ON position. Important If an ammeter other than the J 39200 is used, ensure that the vehicle does not have a high current drain that would damage the ammeter when connected to the circuit. 17. Perform the following procedure in order to detect a high current drain: A. Set the ammeter J 39200 to the 10 A scale. B. Connect the ammeter to the test switch terminals. C. Turn OFF the test switch. This allows the current to flow through the ammeter. D. Wait one minute, then inspect the current reading. Ñ When there is a current reading of 2 A or less, turn ON the test switch, this maintains continuity in the electrical system. Ñ Then, switch the meter down to the 2 A scale, for a more accurate reading, when the test switch is reopened. E. Open the test switch. F. Take the reading in milliamps. G. Note the battery reserve capacity. Refer to Battery Usage . Ñ Divide this number by 4. Example: 90/4 = 22.5 Ñ Compare this to the ammeter reading. Ñ The current drain in milliamps should not exceed this number. Ñ Example: if a battery has a reserve capacity of 90 minutes, the current drain should not exceed 22 milliamps. H. When the current draw is too high, remove the electrical system fuses one at a time until the draw returns to a value less than or equal to specifications. Ñ Start with the fuses that are hot all the time. Ñ To remove the fuse, you must first open the door, which causes a high enough current flow to damage the ammeter. Ñ Protect the ammeter, without disturbing the electrical continuity, by turning ON the test tool before opening the door. Ñ Remove the courtesy lamp fuse. Ñ Note the ammeter reading. Ñ If the parasitic load is still excessive, start removing the remaining fuses one at a time. Ñ Keep the courtesy lamp fuse out during diagnosis, so the door can remain open. Ñ Perform Steps 11 through 13 each time a fuse is removed. I. Removing the PCM or VCM fuse should cause a drop of less than 10 milliamps. A drop greater than 10 milliamps indicates a possible short to ground. J. Check the orange wires along with the components connected to the orange wires. No drop in the milliampere reading indicates the PCM or VCM is not drawing current. K. Repeat the parasitic current drain test procedure after any repair has been completed. L. When the cause of the excessive current draw has been located and repaired, remove the ammeter and the parasitic draw test switch.

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Ford Mondeo Cluster Instrument Cluster REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 16-02-2012

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Removal Note: If a new instrument cluster is being installed connect WDS. Upload the instrument cluster configuration information using the programmable modules installation routine prior to commencing the removal of the instrument cluster. µ 1. Remove the instrument panel lower panel. 1 Remove the retaining screws. 2 Release the retaining clips. µ 2. Detach the audio control switch from the steering column lower shroud (if equipped). z Using a thin bladed screwdriver, release the locking tang. µ 3. Remove the audio control switch (if equipped). z Disconnect the electrical connector. µ 4. Detach the steering column upper shroud. 1 Using a thin bladed screw driver, release the two clips (one each side). 2 Detach the shroud. µ 5. Remove the steering column upper shroud. µ 6. Remove the steering column lower shroud. µ 7. Remove the instrument cluster finish panel retaining screws. (Steering wheel shown removed for clarity). µ 8. Remove the instrument cluster finish panel. µ 9. Remove the instrument cluster retaining screws and detach the instrument cluster. µ 10. CAUTION: The instrument cluster must be kept upright to avoid silicone liquid leaking from the gauges. Remove the instrument cluster. 1 Release the locking tang. 2 Disconnect the instrument cluster electrical connector. Installation Note: If a new instrument cluster is being installed connect WDS. Download the instrument cluster configuration information using the programmable modules installation routine after the installation of the instrument cluster. 1. To install, reverse the removal procedure

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1999 GMC Truck Yukon PRNDL Display Inaccurate or Inoperative PRNDL Inaccurate Repair Manual

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Filed Under (GMC Manuals) by admin on 15-02-2012

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Did you perform the Instrument Cluster System Check? — Go to Step 2 Go to Instrument Cluster System Check 2 1. Disconnect the Transmission Range (TR) Switch connector C2. 2. Turn the ignition switch to the RUN position. 3. Conduct the PRNDL Logic Input Test by connecting fused jumper wires between ground and the appointed cavities of the TR Switch connector. Refer to PRNDL Logic Input Test PRNDL Logic Input Test . 4. Repeat for each transmission range. Do all ranges illuminate? — Go to Step 3 Go to Step 4 3 Adjust the transmission range switch. Refer to Park/Neutral Position Switch Adjustment (4L60E); Park/Neutral Position Switch Adjustment (4L80E) Automatic Transmissions. Replace the PNP Switch. Refer to Park/Neutral Position Switch Replacement (4L60E); Park/Neutral Position Switch Replacement (4L80E) in Automatic Transmissions. Is the repair complete? — Go to Instrument Cluster System Check — 4 1. Remove the I/P Cluster. 2. Connect a J 39200 DMM (continuity) between the I/P Cluster connector and connector C2 of the TR Switch to those circuit(s) that connected to the faulty PRNDL indicators. Is continuity present in the circuit(s) tested? — Go to Step 6 Go to Step 5 5 Locate and repair the open in the circuit(s) that are faulty between the TR Switch and the I/P Cluster. Refer to Wiring Repairs in Wiring Systems. Is the repair complete? — Go to Instrument Cluster System Check — 6 Connect a J 39200 DMM (continuity) between the I/P Cluster connector and ground to those circuit(s) that connected to the faulty PRNDL indicators. Is continuity present in the circuit(s) tested? — Go to Step 7 Go to Step 8 Locate and repair the short to ground in the circuit(s) that are faulty between the TR Switch and the I/P Cluster. Refer to Wiring 7 Repairs in Wiring Systems. Is the repair complete? — Go to Instrument Cluster System Check — 8 Replace the I/P Cluster. Refer to Instrument Panel Cluster (IPC) Replacement . Is the repair complete?

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Special Coverage Adjustment – Instrument Panel Cluster Gauge Needle Function

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Filed Under (More Manuals) by admin on 04-01-2012

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2003-2004 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT (U.S. ONLY) 2003-2004 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE 2005 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE (U.S.ONLY) 2003-2004 GMC SIERRA, YUKON, YUKON XL 2005 GMC SIERRA, YUKON, YUKON XL (U.S. ONLY) . Install the IPC. Ensure everything is connected properly. The replacement IPC requires SPS Programming and IPC Setup procedures to be performed. It does not matter which procedure is performed first. 2. Start the engine and then select IPC Setup. You must have the engine running before performing the IPC Setup. 3. Select IPC Setup. With the engine running, enter the appropriate mileage and engine hours. 4. Select “OK”. Review the pop up asking you to verify the mileage and engine hours. Move the pop up out of the way if necessary to view the verification screen. This may require a click and drag of the dialog box. 5. Verify that the mileage and engine hours are correct and select “OK”. DO NOT turn the ignition OFF until the engine has “run” for approximately seven (7) minutes. Allowing the engine to idle for this period of time allows the IPC to accumulate 1/10th of an hour and write the correct engine hour value to the permanent memory. The engine must be running before set up is performed and run for approximately seven minutes after the user selects “OK” confirming their mileage/engine hour inputs. After approximately seven minutes, shut the engine OFF and complete the event. The seven minute clock starts after you select “OK”, confirming the entries. Note: Based on feedback from technicians, we are currently making changes to the “IPC Setup” application which will include several enhancements to the set up screens. These are scheduled to be released and available in TIS2WEB very soon. Important: Only IPC conditions listed in the Condition section of the bulletin are covered under this special coverage program. In a small number of vehicles, the condition may be intermittent and the gauge sweep test may not always verify the condition. IPC Performance IPC performance may be affected by the following conditions: Customer Comments and Observations Customers who describe gauge performance as jumpy, sticky, slow or erratic. Gauge performance may also be described as being inoperative or inaccurate. For example, for a period of time the speedometer may appear to move normally but be inaccurate and not return to zero (0) after the vehicle comes to a stop. This inaccurate condition may be more or less pronounced during the drive cycle and may, for a time, return to normal operation. A Tech 2 sweep test may not reveal the condition. 1. Perform a gauge sweep test to determine/verify that an IPC gauge is sticking, stuck, or inoperative. Using the Tech 2, navigate to the following screens to perform the gauge sweep test: Body -> Instrument Panel Cluster -> Special Functions -> IPC Gauges -> Display(s) Test. • Cold temperatures • Temperature fluctuations • High humidity • Driving over rough surfaces such as dirt roads or potholes

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1993 Ford Escort CIRCUIT TEST J – FUEL PUMP CIRCUIT (RELAY AND INERTIA SWITCH)

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Filed Under (Ford Manuals) by admin on 19-01-2012

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resistance between test pin No. 22 and test pins No. 40 and 60. If resistance is less than 10,000 ohms, repair short circuit and repeat QUICK TEST. If resistance is 10,000 ohms or more, go to step 5). 5)Check Fuel Pump Circuit Continuity Turn ignition off. Leave fuel pump relay and PCM disconnected. Measure resistance between FUEL PUMP circuit at fuel pump relay wiring harness connector and test pin No. 22 at breakout box. If resistance is less than 5 ohms, replace PCM and repeat QUICK TEST. If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST. 10)Code 95/542 A KOEO Code 95/542 indicates one of the following conditions: Engine Starts: * Fuel pump secondary circuit shorted to power. * Fuel pump relay contacts always closed. * Open FPM circuit between PCM and junction to POWER-TO-PUMP circuit. * Left/front HO2S short to power (dual HO2S applications). * Faulty PCM. No Start: * IFS switch circuit open or not reset. * Open circuit in or between PCM and fuel pump. * Faulty ground connection at fuel pump. * Faulty fuel pump. If engine starts, go to step 11). If engine does not start, go to step 15). 11)Check Fuel Pump Operation Turn ignition on. Wait 5 seconds. Listen for fuel pump operation. If fuel pump is off, go to step 13). If fuel pump is on, go to step 12). 12)Check For Fuel Pump Relay Always Closed Turn ignition off. Disconnect fuel pump relay. Turn ignition on. If fuel pump is off with relay disconnected, replace fuel pump relay and repeat QUICK TEST. If fuel pump is on with relay disconnected, repair short to power in POWER-TO-PUMP or FPM circuit. (For models with relay block, also check fuel pump prime plug circuit). Repeat QUICK TEST. 13)Check Continuity Of Fuel Pump Monitor (FPM) Circuit Turn ignition off. Disconnect PCM 60-pin connector. Inspect and repair any damaged terminals. Install EEC-IV Breakout Box (T83L-50-EEC-IV) , leaving PCM disconnected. Disconnect fuel pump relay. Measure resistance between test pin No. 8 (No. 19 on Escort, and Tracer) at breakout box and POWER-TO-PUMP circuit at fuel pump relay wiring harness connector. If resistance is less than 5 ohms, go to step 25) (dual HO2S) or replace PCM and repeat QUICK TEST (single HO2S). If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST

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2004 Ford Explorer/Mountaineer Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index Repair Manual

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Filed Under (Ford Manuals) by admin on 20-05-2011

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C1963 Stability Control Inhibit Warning ABS Module This DTC is for information only. CLEAR the DTC. REPEAT the self-test. C1991 Module Calibration Failure ABS Module Follow the diagnostic tool directions for the calibration procedure. C1996 Active Yaw Control Disabled ABS Module This DTC will be set if the stability assist system is activated for 15 seconds of continuous operation. CHECK for any major chassis modifications, gross suspension misalignment, or other items that can alter the vehicle tracking dynamics. CLEAR the DTC. REPEAT the self-test. C1998 Module Calibration Not Complete ABS Module Go To Pinpoint Test Q . C2769 (ABS only) Longitudinal Acceleration Sensor Circuit Failure ABS Module CLEAR the DTC. REPEAT the self-test. If DTC C2769 is present, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. C2769 (ABS with stability assist) Longitudinal Acceleration Sensor Circuit Failure ABS Module Go To Pinpoint Test H . C2770 (ABS with Stability Assist) Longitudinal Acceleration Sensor Signal Fault ABS Module Go To Pinpoint Test H . C2770 (ABS only) Longitudinal Acceleration Sensor Signal Fault ABS Module CLEAR the DTC. REPEAT the self-test. If DTC C2770 is present, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. C2777 Sensor Cluster Bus Failure ABS Module Go To Pinpoint Test H . C2778 Sensor Cluster Power Supply Failure ABS Module Go To Pinpoint Test H . U1900 CAN Communication Bus Fault-Receive Error Network Fault Section 418-00 . U1901 CAN Network #2 Communication Bus Fault- Receive Error Network Fault Go To Pinpoint Test H . U2023 Fault received from external node Network Fault Section 418-00

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Battery Electrical Drain/ Parasitic Load Test

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Filed Under (More Manuals) by admin on 25-04-2012

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1. Disconnect the battery negative cable. 2. Install the male end of the J 38758 to the negative battery terminal. 3. Turn OFF the test switch. 4. Install the negative battery cable to the female end of the test switch. 5. Install the Scan Tool (or equivalent) or wait for 20 minutes. 6. Turn ON the test switch. 7. Road test the vehicle while activating all accessories, including the radio and the air conditioning. 8. Lower the door glass, then exit the vehicle. Do not move the door handle after closing the door. 9. Open the hood. Important The power down timer will reset to 20 minutes if any wake up inputs are received by a Class 2 device (after the scan tool has put all Class 2 devices to sleep). 10. Put all of the Class 2 devices into the sleep mode. 11. Turn OFF the ignition switch. Remove the key. Important From this point on, electrical continuity must be maintained in the ground circuit of the battery through the Test Switch J 38758 in the ON position or through the ammeter J 39200 . 12. Components such as PCM, VCM, Automatic Air Conditioning, and the Truck Body Control Module have timers that draw several amps of current while they cycle down. This can give a false parasitic drain reading. Wait 20 minutes for these components to power down before continuing this test (or use the scan tool to put all Class 2 devices to sleep). 13. Connect a jumper wire with a 10 A fuse J 36169-A to the terminals of the test switch. 14. Turn the test switch to the OFF position. 15. Wait ten seconds. If the fuse does not blow, the current is less than 10 A. The ammeter can be used safely. 16. Before the fused jumper wire is removed, turn the test switch to the ON position. Important

Ford Triton 4.6L, 5.4L, and 6.8L Spark Plug Thread Repair Manual

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Filed Under (Ford Manuals) by admin on 24-03-2011

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CAUTION: If spark plug thread repair is being done in vehicle make sure the piston is 1/3 – 1/2 way down the bore on the down stroke. This will ensure the valves are closed to help reduce contamination and avoid any interference with the core drill. Cleaning and Identifying the Head Type 1. Remove spark plug from a good spark plug hole, chuck the FT5FTCB brush supplied in the kit into a slow speed drill, and clean the bottom of the hole. Note: If procedure is being done in vehicle clean hole using a vacuum cleaner to remove debris . Gauge the spark plug hole using FT5CG Tooling Type Gauge; this is to be used as a comparison when gauging the defective spark plug hole in step number 4. Pull down on the gauge until the snap ring seats against the top of the probe. 2. Perform Steps 2 through 4 to determine cylinder head Type: Cleaning: Identifying: Caution: Do not use the brush to clean the hole after the repair insert has been installed. 3 of 14 3. Push the gauge down into the spark plug well until it seats firmly at the bottom. Make sure that the upper part of the tool is up high enough to allow the gauge to reach the bottom of the hole. Allow the upper alignment bushing to center the tool in the hole. Let the rod float in the upper alignment bushing without tightening the thumb screw. 4. Pull the gauge up out of the well and read the chart on the side of the gauge by comparing the portion of the gauge that is exposed when pushed into the the spark plug hole to determine if the head is Type 1, 2, or 3. Note: the difference between Type 1 and Type 3 is small. Double check to make sure the reading repeats. If your gauge readings are in question remove another spark plug from a good hole and compare gauge readings.

1995 Toyota 4Runner STARTING AND CHARGING SYSTEMS REPAIR MANUAL

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Filed Under (Toyota Manuals) by admin on 15-03-2012

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TROUBLE SHOOTING NOTE: See TROUBLE SHOOTING – BASIC PROCEDURES article in GENERAL INFORMATION. 1) If a no-start condition exists and battery is known to be good, connect test light or voltmeter between starter solenoid terminal No. 50 and ground. See Figs. 6 and 7. 2) Turn ignition switch to START position. If test light or voltmeter does not indicate voltage, check main fusible links and large ampere main fuses in engine compartment relay box. If fusible links and fuses are okay, see IGNITION SWITCH CONTINUITY TEST and/or STARTER RELAY TEST under ON-VEHICLE TESTING. ON-VEHICLE TESTING NOTE: Before testing, ensure battery is fully charged, battery cables and terminal ends are tight and clean, and engine grounds are secure. CLUTCH START SWITCH TEST 1) Switch is located above clutch pedal on bracket. Disconnect wiring harness connector from switch. 2) Connect ohmmeter probes to switch terminals. Depress clutch pedal. If continuity does not exist, adjust or replace clutch start switch. If continuity exists, check circuit to starter relay for open, and check starter relay. See STARTER RELAY TEST. CLUTCH START CANCEL SWITCH TEST 1) Locate switch in left dash panel. Remove right lower instrument panel to access switch connector. Disconnect wiring harness connector from switch pigtail connector. See Fig. 1. 2) Connect negative lead of ohmmeter to terminal No. 1. Ensure continuity does not exist between connector terminals No. 1 and 2, terminals No. 1 and 3, and terminals No. 2 and 3. Check operation of switch by connecting jumper wires from 12-volt battery. Connect positive lead to terminal No. 3 and negative battery lead to terminal No. 1. 3) Using ohmmeter, ensure continuity does not exist between connector terminals No. 1 and 2 until switch button is pushed. When switch button is pushed, switch light should come on and continuity should exist. Disconnect battery and ensure continuity does not exit between terminals No. 1 and 2. If switch does not test as specified, replace switch. Fig. 1: Identifying Clutch Start Cancel Switch Connector Terminals Courtesy of Toyota Motor Sales, U.S.A., Inc. IGNITION SWITCH CONTINUITY TEST WARNING: Deactivate air bag system before performing any service operation. For 1996 4Runner, see AIR BAG RESTRAINT SYSTEM article. 1995 1) Disconnect negative battery cable. Removedriver’s lower instrument panel cover. Remove upper and lower steering column covers if needed. Locate ignition switch wiring harness 8-pin connector. See Figs. 2-3. 2) With ignition switch in LOCK position, there should be no continuity between any terminals. With ignition switch in ACC position, there should be continuity between terminals No. 2 and 3. With ignition switch in ON position, there should be continuity between terminals No. 1, 2 and 3, and between terminals No. 7 and 8. 3) With ignition switch in START position, there should be continuity between terminals No. 1, 4 and 6, and between terminals No. 7 and 8. If continuity is not as specified, replace switch.

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