A/C, Engine Controls - MIL ON/DTC P2135 Set

TSB 09-22-4

11/16/09

DTC P2135 - BUILT BETWEEN 5/1/2009 AND 7/21/2009

FORD:
2009-2010 Explorer

MERCURY:
2009-2010 Mountaineer

ISSUE
Some 2009-2010 Explorer and Mountaineer vehicles built between 5/1/2009 and 7/21/2009 and equipped with 4.0L engine and auxiliary climate control may have a malfunction indicator lamp (MIL) on with a diagnostic trouble code (DIC) P2135 due to incorrect orientation of the heater hose. The vehicle may also exhibit a reduction in power or hesitation.

ACTION
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

1. Verify DTC P2135 is present.





2. Check the clearance between the heater inlet hose and the throttle position sensor (IPS) connector and wiring. (Figure 1)

a. If the clearance is more than 3/8" (10 mm), follow normal diagnostics.

b. If the hose is touching the wiring or the clearance is 3/8" (10 mm) or less, proceed to Step 3.

3. Relieve cooling system pressure, Refer to Work Shop Manual (WSM), Section 303-03.

4. Remove the spring clamp at the heater core outlet tube connection and rotate hose clockwise until the hose is oriented as shown in the picture and install the spring clamp. There should be about 13/16" - 1 3/16" (20-30 mm) clearance between the hose and the IPS connector and wiring harness. In addition, the hose must have clearance to all clamps on the other heater hose.

5. Inspect the wires at the IPS connector where the hose was contacting. If the wires are worn, repair as needed.

6. Top off engine coolant as needed.

7. Clear DTC's.

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

092204A 2009-2010 Explorer, 0.4 Hr.
Mountaineer 4.0L: Rotate
The Heater Hose Following
The Service Procedure (Do
Not Use With Any Other
Labor Operations)

092204B 2009-2010 Explorer, 0.6 Hr.
Mountaineer 4.0L: Rotate
The Heater Hose; Repair
Wires At The TPS
Connector Following The
Service Procedure (Do Not
Use With Any Other Labor
Operations)

DEALER CODING
CONDITION
BASIC PART NO. CODE
18472 12





Disclaimer