Repair and Diagnosis: Description and Operation
Using This Information
Introduction
This information describes and directs repair procedures for this vehicle model year. It includes diagnostics for all vehicle systems except driveability and emission control. Refer to the separate Computers and Control Systems Information for driveability and emission control diagnostics.
Information is organized into groups, with systems that have subsections dividing them.
Warnings, Notices, and Notes
Warnings provide information to avoid personal injury and to make sure service actions on critical safety systems are performed correctly.
Notices provide information to avoid damage to the vehicle or a component.
Notes provide information critical for a complete and effective repair.
Warnings that apply to an entire system or diagnostic/repair information system are located in Service Information Description and Operation Safety Warnings Service Precautions.
Warnings, Notices, or Notes that apply to an entire procedure will be placed at the beginning of the procedure.
Warnings, Notices, or Notes that apply to a single step are placed at the beginning of the step. Those that apply to a group of steps will be placed at the first step requiring it.
Vehicle and Engine Orientation Identifiers
LH and RH vehicle designations are oriented from the driver's seat position looking forward. LH and RH engine designations are oriented from the flywheel position looking towards the crankshaft pulley.
How to Use Diagnostic Information
DTC and Symptom Charts
Module DTC Charts are used to begin and direct the diagnosis of a DTC. Symptom Charts contain concern symptoms and direct solutions either in the chart or in a linked Diagnostic Routine. Both DTC and Symptom Charts may provide the solution within the chart, or provide a link to the appropriate Diagnostic Routine.
In some systems, the Symptom Chart is preceded by a Preliminary Inspection which must be followed prior to using the Symptom Chart
Using Module DTC Charts
This diagnostic/repair information contains diagnostics for DTCs set by vehicle modules. Driveability and emission DTCs are covered in the separate Computers and Control Systems Information. If a PCM-set DTC is not listed in the diagnostic/repair information, it is serviced in Computers and Control Systems Information.
DTC diagnostics are found in both on-line and printed publications and are used as follows:
- On-line publications: Using the left side menu, click on the Master DTC Chart link to view the vehicle module DTC charts. Each module has a chart with links or in-chart solutions for all DTCs diagnosed in the diagnostic/repair information.
- Printed publications: Use the DTC index in the rear of the book.
Diagnostic Methods
Diagnostic Methods provides information to support diagnosing Ford vehicles. Diagnostic strategies, diagnostic tool support information, and advanced circuit testing methods are included. REFER to Diagnostic Methods .
Diagnostic Routines
Diagnostic Routines provide information to determine the root cause of concerns addressed in either a DTC Chart or Symptom Chart. Each Diagnostic Routine contains:
- Diagnostic Overview
- Wiring Diagram References (as applicable)
- Normal Operation and Fault Conditions
- Visual Inspection and Diagnostic Pre-checks
- Tool Table (as applicable)
- Material Table (as applicable)
- Pinpoint Test Steps
Component Tests
Component Tests are used to separately analyze a single common component in a system. The test will determine if the part is functioning correctly.
Mechanical Procedures Such As Removal and Installation
Reuse Of Fasteners, Seals, Or Gaskets
The following is a list of assumptions made in the reuse of fasteners, seals, or gaskets.
- Seals and gaskets must be replaced unless otherwise specified.
- Standard fasteners are reused unless otherwise specified.
- Fasteners with self-locking features must be replaced unless otherwise noted. Reminder text may or may not be included with the procedure step. Examples of fastener coatings or fasteners with mechanical locking (with the locking features highlighted yellow) are shown in illustration 1.
- Torque to yield bolts (bolts with more than one stage of tightening torque and a final torque angle specification) must be discarded and new torque to yield bolts installed unless otherwise stated within the procedure.
Illustration 1 - self-locking coatings or locking feature are highlighted yellow
Graphics
Illustrations may be used to replace written step instructions. Color-coding (see color scheme in this document) is used to communicate the required step action or actions. Service action icons (see Symbols Glossary Symbols Glossary) are used to add additional information regarding the required action.
- The color scheme in a step graphic (an illustration used in removal or installation steps) indicates servicing information as follows:
- Fasteners (including panel retainers) or electrical connectors- Magenta (Purple)
- Target component that is to be removed- Blue
- Components that must be removed prior to the target component shown in blue- Brown or Green
- Components placed aside for access, but not removed; highlighted areas such as inspection areas, adjustments or measurements- Yellow
- Essential Special Service Tools (ESSTs) and other tools- Pale Blue
- Chemical or Sealer apply areas- Alternating blue and white dashes (see illustration 4)
- Sectioned or cut-away areas- Red
- Remaining components- Grey
Callouts in graphics indicate removal (or tightening) order, or identify individual instructions in substeps of the same number (such as different torque values).
Arrows containing x numbers (Illustration 2) indicate the number of identical fasteners or connectors to be removed or installed in the graphic.
In Illustration 2, two identical fasteners are indicated by the x2 arrow, with another arrow illustrating a third fastener of a different type. Because the different fasteners require different torques, callouts are used to identify those two torque values in the associated step text. The hose clamp is another fastener to be removed. The yellow coloring of the hose indicates it is to be moved aside (not removed).
The following written steps would be necessary if the illustration did not have color coding:
1. Remove the engine oil pipe fastener at the engine connection.
2. Remove the two engine oil pipe fasteners from the turbocharger and remove the pipe.
3. Remove the air inlet hose from the turbocharger and position aside.
Illustration 2
Hidden fasteners, such as panel retainers, are identified in the illustration by a magenta disc. An inset detail view illustrating the fastener type may be included (Illustration 3).
Illustration 3 - Note motion arrow at panel bottom; it indicates to lift panel up, then move inward to remove
Symbols
Symbols may be used inside graphics or in the text area to communicate service actions. The following examples demonstrate the use of some of these symbols. REFER to Symbols Glossary Symbols Glossary for a complete symbols list with explanations.
In the Illustration 4 example, service action symbols are shown as used to direct the application of sealer, lubricant, weight, tape or cleaning detergent to a component. In this example a bead diameter of "xx" millimeters is prescribed. The blue and white dashes indicate where the material is applied.
Illustration 4
Illustration 5 is an example of location symbols used to show the location of a component or system within the vehicle.
Illustration 5
Illustration 6 shows how gearshift lever or selector lever position symbols may be used to indicate the gearshift lever or selector lever position required. The required Essential Special Service Tool to align the shift mechanism is shown in pale blue and identified by ESST number.
Illustration 6
Callouts or arrows may be used to identify components for supporting special information, such as a required sequence or to indicate a number of identical components. Illustration 7 shows a removal order in the top graphic and the bottom graphic indicates 12 identical bolts.
Illustration 7
Standard tool symbols direct the use of standard tools to perform a service action, such as the cutting of carpet shown in Illustration 8. Tool symbols may include dimensional values (for example, a drill with a specified diameter).
Illustration 8
