2003.

0 Mondeo
Workshop Manual
Table of Contents
Accessory Drive 303-05
Starting System 303-06
Engine Ignition 303-07A
Group 1 General Information Engine Ignition 303-07B
Service Information Engine Emission Control 303-08
General Information 100-00 Intake Air Distribution and Filtering 303-12
Identification Codes 100-01 Evaporative Emissions 303-13
Jacking and Lifting 100-02 Electronic Engine Controls 303-14
Noise, Vibration and Harshness 100-04 Automatic Transmission/Transaxle
Automatic Transmission/Transaxle 307-01A
Automatic Transmission/Transaxle 307-01B
Group 2 Chassis Transmission/Transaxle Cooling 307-02A
Suspension Transmission/Transaxle Cooling 307-02B
Suspension System - General 204-00 Automatic Transmission/Transaxle 307-05A
Information External Controls
Front Suspension 204-01 Automatic Transmission/Transaxle 307-05B
Rear Suspension 204-02 External Controls
Wheels and Tires 204-04 Exhaust System
Driveline Exhaust System 309-00
Front Drive Halfshafts 205-04 Fuel System
Brake System Fuel System - General Information 310-00
Brake System - General Information 206-00 Fuel Tank and Lines 310-01
Front Disc Brake 206-03 Acceleration Control 310-02
Rear Disc Brake 206-04 Speed Control 310-03
Parking Brake and Actuation 206-05
Hydraulic Brake Actuation 206-06 Group 4 Electrical
Power Brake Actuation 206-07
Anti-Lock Control 206-09A Climate Control System
Anti-Lock Control - Stability Assist 206-09B Climate Control System - General 412-00
Information
Steering System
Steering System - General 211-00 Air Distribution and Filtering 412-01
Information Heating and Ventilation 412-02A
Power Steering 211-02 Auxiliary Heating 412-02B
Steering Linkage 211-03 Air Conditioning 412-03
Steering Column 211-04 Control Components 412-04
Instrumentation and Warning Systems
Instrument Cluster and Panel 413-00
Group 3 Powertrain Illumination
Instrument Cluster 413-01
Engine
Engine System - General Information 303-00 Horn 413-06
Engine 303-01A Clock 413-07
Engine 303-01B Information and Message Center 413-08
Engine Cooling 303-03 Warning Devices 413-09
Fuel Charging and Controls 303-04A Battery and Charging System
Charging System - General 414-00
Fuel Charging and Controls 303-04B
Information
08/2002 2003.0 Mondeo
 Battery, Mounting and Cables 414-01 Group 5 Body and Paint
Generator and Regulator 414-02
Entertainment Systems Body
Entertainment System - General 415-00 Front End Body Panels 501-02
Information Body Closures 501-03
Audio Unit 415-01 Interior Trim and Ornamentation 501-05
Antenna 415-02 Rear View Mirrors 501-09
Speakers 415-03 Seating 501-10
Lighting Glass, Frames and Mechanisms 501-11
Exterior Lighting 417-01 Instrument Panel and Console 501-12
Interior Lighting 417-02 Handles, Locks, Latches and Entry 501-14
Electrical Distribution Systems
Module Communications Network 418-00 Wipers and Washers 501-16
Module Configuration 418-01 Roof Opening Panel 501-17
Electronic Feature Group Bumpers 501-19
Anti-Theft - Passive 419-01B Safety Belt System 501-20A
Cellular Phone 419-08 Supplemental Restraint System 501-20B
Multifunction Electronic Modules 419-10 Frame and Mounting
Uni-Body, Subframe and Mounting 502-00
System

The illustrations, technical information, data and No part of this publication may be produced, stored in a
descriptive text in this issue, to the best of our retrieval system or transmitted in any form, electonic,
knowledge, were correct at the time of going to print. mechanical, photocopying, recording, translating or by
The right to make changes at any time, without notice, any means without prior wirtten permission of Ford
is reserved as part of Ford's policy of continuous Motor Company Ltd/Ford Werke AG.
development and improvement. (c) Ford Motor Company Ltd/Ford Werke AG 1998
No liability can be accepted for any inaccuracies or Produced by:
omissions in this publication, although every possible
Reiner Winters GmbH
care has been taken to make it as complete and accute
D-57537 Wissen/Sieg
as possible.
Germany
Published by Ford Motor Company Ltd/Ford Werke AG.
Order code: CGen (Please quote when re-ordering)
This publication is printed on totally chlorine-free (TCF)
paper i.e. material that has been bleached without the
use of chlorine gas or chlorine-based chemicals.

08/2002 2003.0 Mondeo

 Group

SECTION TITLE PAGE

Service Information
General Information............................................................................................................... 100-00-1
Identification Codes............................................................................................................... 100-01-1
Jacking and Lifting................................................................................................................. 100-02-1
Noise, Vibration and Harshness ............................................................................................ 100-04-1

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100-00-1 General Information 100-00-1

SECTION 100-00 General Information

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

About This Manual............................................................................................................. 100-00-3

Introduction ...................................................................................................................... 100-00-3
Replacement Parts........................................................................................................... 100-00-3
Special Tools.................................................................................................................... 100-00-3
Important Safety Instructions ............................................................................................ 100-00-3
Warnings, Cautions and Notes in This Manual ................................................................. 100-00-3
How to Use This Manual .................................................................................................. 100-00-3
Samples ........................................................................................................................... 100-00-4
Health and Safety Precautions .......................................................................................... 100-00-5
Introduction ...................................................................................................................... 100-00-5
Acids and Alkalis .............................................................................................................. 100-00-5
Air Bags............................................................................................................................ 100-00-5
Air Conditioning Refrigerant.............................................................................................. 100-00-6
Adhesives and Sealers..................................................................................................... 100-00-6
Antifreeze ......................................................................................................................... 100-00-7
Asbestos .......................................................................................................................... 100-00-7
Battery Acids .................................................................................................................... 100-00-7
Brake and Clutch Linings and Pads.................................................................................. 100-00-7
Brakes Fluids (Polyalkylene Glycols)................................................................................ 100-00-7
Brazing............................................................................................................................. 100-00-7
Chemical Materials........................................................................................................... 100-00-7
Chlorofluorocarbons (CFC) .............................................................................................. 100-00-9
Clutch Fluids .................................................................................................................... 100-00-9
Clutch Linings and Pads................................................................................................... 100-00-9
Corrosion Protection Materials ......................................................................................... 100-00-9
Cutting.............................................................................................................................. 100-00-9
Dewaxing ......................................................................................................................... 100-00-9
Dusts................................................................................................................................ 100-00-9
Electric Shock .................................................................................................................. 100-00-9
Engine Oils....................................................................................................................... 100-00-10
Exhaust Fumes ................................................................................................................ 100-00-10
Fibre Insulation................................................................................................................. 100-00-10
Fire................................................................................................................................... 100-00-10
First Aid............................................................................................................................ 100-00-10
Fluoroelastomer ............................................................................................................... 100-00-10
Foams - Polyurethane ...................................................................................................... 100-00-10
Freon................................................................................................................................ 100-00-11
Fuels ................................................................................................................................ 100-00-11
Gas Cylinders................................................................................................................... 100-00-12
Gases............................................................................................................................... 100-00-12
Gaskets (Fluoroelastomer) ............................................................................................... 100-00-12
General Workshop Tools and Equipment ......................................................................... 100-00-12
High Pressure Air, Lubrication and Oil Test Equipment .................................................... 100-00-12
Halon................................................................................................................................ 100-00-12
Legal Aspects................................................................................................................... 100-00-12
Lubricants and Greases ................................................................................................... 100-00-13

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100-00-2 General Information 100-00-2

Noise ................................................................................................................................ 100-00-14

Noise Insulation Materials ................................................................................................. 100-00-14
O-Rings (Fluoroelastomer)................................................................................................ 100-00-14
Paints................................................................................................................................ 100-00-14
Pressurized Equipment ..................................................................................................... 100-00-14
Solder ............................................................................................................................... 100-00-14
Solvents............................................................................................................................ 100-00-14
Sound Insulation ............................................................................................................... 100-00-15
Suspended Loads ............................................................................................................. 100-00-15
Transmission Brake Bands ............................................................................................... 100-00-15
Underseal ......................................................................................................................... 100-00-15
Viton ................................................................................................................................. 100-00-15
Welding............................................................................................................................. 100-00-15
Warning Symbols on Vehicles........................................................................................... 100-00-16
White Spirit ....................................................................................................................... 100-00-17
Standard Workshop Practices............................................................................................ 100-00-18
Vehicle in Workshop ......................................................................................................... 100-00-18
Alternative Fuel ................................................................................................................. 100-00-18
Alternative Fuel — Do's .................................................................................................... 100-00-18
Alternative Fuel — Do Nots............................................................................................... 100-00-18
Towing the Vehicle............................................................................................................ 100-00-19
Connecting a Slave Battery Using Jumper Cables ............................................................ 100-00-19
Component Cleaning ........................................................................................................ 100-00-20
Calibration of Essential Measuring Equipment .................................................................. 100-00-20
Solvents, Sealers and Adhesives ....................................................................................... 100-00-21
Introduction ....................................................................................................................... 100-00-21
General Specifications ...................................................................................................... 100-00-21
Road/Roller Testing ........................................................................................................... 100-00-22
Pre-Test Checks ............................................................................................................... 100-00-22
Starting the Engine ........................................................................................................... 100-00-22
On Road or Roller Test Check: ......................................................................................... 100-00-22
Brake Testing.................................................................................................................... 100-00-23

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100-00-3 General Information 100-00-3

DESCRIPTION AND OPERATION

About This Manual

DESCRIPTION AND OPERATION

that only genuine Ford or Motorcraft parts are

installed during service or repair.
Introduction
This manual has been written in a format that is
Special Tools
designed to meet the needs of Ford technicians
worldwide. The objective is to use common The Special Tool(s) Table provided at the
formats and include similar content in each beginning of each procedure shows all special
manual worldwide. tools required to carry out a repair. Where
possible, illustrations are provided to assist in
This manual provides general descriptions for
identifying the special tool required.
accomplishing service and repair work with
tested, effective techniques. Following them will Special tools may be ordered from Loewener
help assure reliability. OTC GmbH, Rotunda Equipment, or their
agents/distributors.

Replacement Parts
Ford and Motorcraft parts are made to the same
exacting standards as the original factory fitted
components. For this reason, it is recommended
Europe North America
Loewener OTC GmbH Rotunda Equipment
Industriestrasse 67 PO Box 1450
D40764 Langenfeld Kenosha W1 53141-1450
Germany Phone 1-800-ROTUNDA
Tel: +49 (0) 2173 928-0 FAX 1-800-762-6181
Fax: +49 (0) 2173 928-199 WWW.FORDROTUNDA.COM

Important Safety Instructions CAUTION: Cautions are used to indicate

Appropriate service methods and correct repair that failure to follow a procedure
procedures are essential for the safe, reliable correctly may result in damage to the
operation of all motor vehicles as well as the vehicle or equipment being used.
personal safety of the individual carrying out the NOTE: Notes are used to provide additional
work. essential information required to carry out a
This manual cannot possibly anticipate all such complete and satisfactory repair.
variations and provide advice or cautions as to As you read through this manual, you will come
each. Anyone who departs from the instructions across WARNINGS, CAUTIONS and NOTES.
provided in this manual must first establish that
he compromises neither his personal safety nor A warning, caution or note is placed at the
the vehicle integrity by his choice of methods, beginning of a series of steps if it applies to
tools or parts. multiple steps. If the warning, caution or note only
applies to one step, it is placed at the beginning
of the specific step (after the step number).
Warnings, Cautions and Notes in This Manual
WARNING: Warnings are used to indicate How to Use This Manual
that failure to follow a procedure This manual covers service and repair
correctly may result in personal injury. procedures.

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DESCRIPTION AND OPERATION (Continued)

This manual is structured into groups and A component test is used when a component is
sections, with specific system sections collected tested in multiple pinpoint tests, or if a procedure
together under their relevant group. is too complicated to be formatted within a single
page of the pinpoint test.
A group covers a specific portion of the vehicle.
The manual is divided into five groups, General Graphics
Information, Chassis, Powertrain, Electrical and
Test graphics show the measurement or test to
Body and Paint. The number of the group is the
be performed in a test step.
first number of a section number.
A representative tester graphic is used for
Pages at the start of the manual list all sections
voltmeters and ohmmeters.
available. Each section has a contents list
detailing General Specifications, Description and If multiple measurements are made in a single
Operation and Service Adjustment and Checks. graphic, the test leads are drawn with a solid line
until the test lead splits to indicate the multiple
If components need to be removed or
measurements, at which point dashed lines are
disassembled in sequence, the sequence will be
used.
identified numerically in a graphic and the
corresponding text will be numbered accordingly Breakout box-type testers are represented by a
(refer to `Samples'). double circle test pin. Test pins are labelled with
the pin number.
All left and right-hand references to the vehicle
are taken from a position sitting in the driver seat
looking forward.
Samples
All left and right-hand references to the engine
Special Tools and Torque Figures
are taken from a position at the flywheel looking
towards the front camshaft pulley. Any requirement for special tools will picture the
tool, showing it in use and with its tool number
Where appropriate, instructions will be given for
shown. Torque settings will be given at the
the use of WDS, FDS2000 or New Generation
relevant point in the procedure.
STAR Tester diagnostic equipment.
Inspection and Verification
Visual Inspection Charts, Symptom Charts and
other information charts (such as diagnostic
routines), supplement test procedures with
technical specifications, or navigate the user to a
specific test procedure.
Sympton Chart
The symptom chart indicates symptoms, sources
and actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are
used to identify the source of a concern in a
logical, step-by-step manner. Pinpoint tests have
two columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for
graphics and icons (with or without captions) and
the DETAILS/RESULTS/ACTIONS column
provides direction to another test step or specific
corrective actions.
The boxed numbers indicate the order in which
the described action is to be performed.
Component Tests

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100-00-5 General Information 100-00-5

DESCRIPTION AND OPERATION

Health and Safety Precautions

module and is completely consumed during

deployment. No attempt should be made to open
Introduction an air bag inflator as this will lead to the risk of
exposure to Sodium Azide. If a gas generator is
Many of the procedures associated with vehicle
ruptured, full protective clothing should be worn
maintenance and repair involve physical hazards
when dealing with the spillage.
or other risks to health. This subsection lists,
alphabetically, some of these hazardous After normal deployment, gloves and safety
operations and the materials and equipment goggles should be worn during the handling
associated with them. Precautions necessary to process.
avoid these hazards are identified. Deployed air bags should be disposed of in a
The list is not exhaustive and all operations and plastic bag in accordance with local regulations at
procedures, and the handling of materials, should an approved chemical waste site.
be carried out with health and safety in mind. Following any direct contact with gas generant.
Before using any product the Materials Safety – wash affected areas thoroughly with water.
Data Sheet supplied by the manufacturer or
supplier should be consulted. – seek medical assistance if necessary.
Air Bags - Do's
– do store modules in an upright position.
Acids and Alkalis
– do keep modules dry.
See also Battery Acids. – do carry modules with the cover side pointing
For example caustic soda, sulphuric acid. away from the body.
Used in batteries and cleaning materials. – do place modules with their cover side
upwards.
Irritant and corrosive to the skin, eyes, nose and
– do carefully inspect modules for damage.
throat. Cause burns. Can destroy ordinary
protective clothing. – do stand to one side when connecting
modules.
Avoid splashes to the skin, eyes and clothing.
– do make sure all test equipment is properly
Wear suitable protective impervious apron,
calibrated and maintained.
gloves and goggles. Do not breath mists.
– do wash hands after handling deployed air
Make sure access to eye wash bottles, shower bags.
and soap are readily available for splashing
accidents. Air Bags - Do Nots
Display Eye Hazard sign.

Air Bags
See also Fire, Chemical Materials
Highly flammable, explosive – observe No
Smoking policy.
Used as a safety restraint system mounted in the
steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT
GAS (2500°C).
The gas generant used in air bags is Sodium
Azide. This material is hermetically sealed in the

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DESCRIPTION AND OPERATION (Continued)

– do not store highly flammable material Highly flammable, flammable, combustible –
together with modules or gas generators. observe No Smoking policy.
– do not store gas generators at temperatures Generally should be stored in No Smoking areas.
exceeding 80°C. Cleanliness and tidiness in use should be
– do not store modules upside down. observed, for example disposable paper covering
– do not attempt to open a gas generator benches; should be dispensed from applicators
housing. where possible; containers, including secondary
containers, should be labelled appropriately.
– do not expose gas generators to open flame
or sources of heat.
– do not place anything on top of a module Solvent-based Adhesives/Sealers - See Solvents
cover. Follow manufacturers instructions.
– do not use damaged modules.
– do not touch a fired module or gas generator
Water-based Adhesives/Sealers
for at least 10 minutes.
– do not use any electrical probes on the wiring Those based on polymer emulsions and rubber
circuit. latexes may contain small amounts of volatile
toxic and harmful chemicals. Skin and eye
contact should be avoided and adequate
Air Conditioning Refrigerant ventilation provided during use.
See also Chlorofluorocarbon, Chemical Materials
Hot Melt Adhesives
Highly flammable, combustible – observe No
Smoking policy. In the solid state, they are safe. In the molten
state they may cause burns and health hazards
Skin contact may result in frostbite. may arise from the inhalation of toxic fumes.
Instructions given by the manufacturer must be Use appropriate protective clothing and a
followed. Avoid naked lights, wear suitable thermostatically controlled heater with a thermal
protective gloves and goggles. cut-out and adequate extraction.
If refrigerant comes into contact with the skin or
eyes, rinse the affected areas with water
Resin-based Adhesives/Sealers, for example
immediately. Eyes should also be rinsed with an
appropriate irrigation solution and should not be Epoxide and Formaldehyde Resin-based
rubbed. SEEK MEDICAL ASSISTANCE IF Mixing should be carried out in well ventilated
NECESSARY. areas, as harmful or toxic volatile chemicals may
be released.
Air Conditioning Refrigerant - Do Nots Skin contact with uncured resins and hardeners
can result in irritation, dermatitis, and absorption
– do not expose refrigerant bottles to sunlight or
of toxic or harmful chemicals through the skin.
heat.
Splashes can damage the eyes.
– do not stand refrigerant bottles upright; when
filling, hold them with the valve downwards. Provide adequate ventilation and avoid skin and
eye contact.
– do not expose refrigerant bottles to frost.
– do not drop refrigerant bottles.
– do not vent refrigerant to atmosphere under Anaerobic, Cyanoacrylate (super-glues) and other
any circumstance. Acrylic Adhesives
– do not mix refrigerants, for example R12 Many are irritant, sensitizing or harmful to the
(Freon) and R134a. skin and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the
manufacturers instructions followed.
Adhesives and Sealers
Cyanoacrylate adhesives (super-glues) MUST
See also Fire, Chemical Materials NOT contact the skin or eyes. If skin or eye
tissue is bonded, cover with a clean moist pad

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DESCRIPTION AND OPERATION (Continued)

and SEEK IMMEDIATE MEDICAL ATTENTION. linked to general, food preparation or drinking
Do not attempt to pull tissue apart. Use in well water supplies.
ventilated areas as vapours can cause irritation
to the nose and eyes.
For two-pack systems see Resin-based and Asbestos
Isocyanate Adhesives/Sealers. See also Warning Symbols on Vehicles at the
end of this subsection.
Isocyanate (Polyurethane) Adhesives/Sealers Breathing asbestos dust may cause lung damage
or, in some cases, cancer.
See also Resin-based Adhesives
Used in brake and clutch linings, transmission
Individuals suffering from asthma or respiratory
brake bands and gaskets. Ford original
allergies should not work with or near these
production and replacement items for this model
materials as sensitivity reactions can occur.
are asbestos free.
Over exposure is irritating to the eyes and
The use of drum cleaning units, vacuum cleaning
respiratory system. Excessive concentrations
or damp wiping is preferred.
may produce effects on the nervous system
including drowsiness. In extreme cases, loss of Asbestos dust waste should be dampened,
consciousness may result. Long term exposure placed in a sealed container and marked for safe
to vapour concentrations may result in adverse disposal. If any cutting or drilling is attempted on
health effects. materials containing asbestos the item should be
dampened and only hand tools or low speed
Prolonged contact with the skin may have a
power tools used.
defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort Battery Acids
and possible damage.
See also Acids and Alkalis.
Any spraying should preferably be carried out in
Gases released during charging are explosive.
exhaust ventilated booths, removing vapours and
Never use naked flames or allow sparks near
spray droplets from the breathing zone.
charging or recently charged batteries.
Wear appropriate gloves, eye and respiratory
Make sure there is adequate ventilation.
protection.

Brake and Clutch Linings and Pads

Antifreeze
See Asbestos.
See also Fire, Solvents.
For example isopropanol, ethylene glycol,
methanol. Brakes Fluids (Polyalkylene Glycols)
Highly flammable, flammable, combustible. See also Fire.
Used in vehicle coolant systems, brake air Splashes to the skin and eyes are slightly
pressure systems, screenwash solutions. irritating. Avoid skin and eye contact as far as
Vapours may be given off from coolant antifreeze possible. Inhalation vapour hazards do not arise
(glycol) when heated. Avoid breathing these at ambient temperatures because of the very low
vapours. vapour pressure.
Antifreeze may be absorbed through the skin in
toxic or harmful quantities. Antifreeze, if Brazing
swallowed, can be fatal and MEDICAL
ATTENTION SHOULD BE SOUGHT See Welding.
IMMEDIATELY.
These products must not be used in any cooling Chemical Materials
or industrial water system which is connected or
See also Legal Aspects.
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DESCRIPTION AND OPERATION (Continued)

Chemical materials such as solvents, sealers, Chemical Materials - Do's
adhesives, paints, resin foams, battery acids,
– Do carefully read and observe hazard and
antifreeze, brake fluids, fuels, oils and grease
precaution warnings given on material
should always be used with caution and stored
containers (labels) and in any accompanying
and handled with care. They may be toxic,
leaflets, posters or other instructions. Material
harmful, corrosive, irritant or highly flammable
health and safety data sheets can be
and give rise to hazardous fumes and dusts.
obtained from manufacturers.
The effects of excessive exposure to chemicals – Do remove chemical materials from the skin
may be immediate or delayed; briefly and clothing as soon as practicable after
experienced or permanent; cumulative; soiling. Change heavily soiled clothing and
superficial; life threatening; or may reduce life have it cleaned.
expectancy.
– Do organise work practices and protective
clothing to avoid soiling of the skin and eyes;
breathing vapours, aerosols, dusts or fumes;
inadequate container labelling; fire and
explosion hazards.
– Do wash before job breaks, before eating,
smoking, drinking or using toilet facilities
when handling chemical materials.
– Do keep work areas clean, uncluttered and
free of spills.
– Do store chemical materials according to
national and local regulations.
– Do keep chemical materials out of the reach
of children.

Chemical Materials - Do Nots

– Do not mix chemical materials except under
the manufacturers instructions; some
chemicals can form other toxic or harmful
chemicals, give off toxic or harmful fumes or
become explosive when mixed together.
– Do not spray chemical materials, particularly
those based on solvents, in confined spaces,
for example when people are inside a vehicle.
– Do not apply heat or flame to chemical
materials except under the manufacturers
instructions. Some are highly flammable and
some may release toxic or harmful fumes.
– Do not leave containers open. Fumes given
off can build up to toxic, harmful or explosive
concentrations. Some fumes are heavier than
air and will accumulate in confined areas
such as pits.
– Do not transfer chemical materials to
unlabelled containers.
– Do not clean hands or clothing with
chemicals. Chemicals, particularly solvents
and fuels, will dry skin and may cause
irritation leading to dermatitis or be absorbed
through the skin in toxic or harmful quantities.

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DESCRIPTION AND OPERATION (Continued)

– Do not use emptied containers for other Dewaxing

materials except when they have been
See Solvents and Fuels (Kerosene).
cleaned under supervised conditions.
– Do not sniff or smell chemical materials. Brief
exposure to high concentrations of fumes can Dusts
be toxic or harmful.
Powder, dusts or clouds may be irritant, harmful
or toxic. Avoid breathing dusts from powdery
Chlorofluorocarbons (CFC) chemical materials or those arising from dry
abrasion operations. Wear respiratory protection
There is concern in the scientific community that if ventilation is inadequate.
CFCs and Halons are depleting the upper ozone
layer which filters out harmful ultraviolet radiation. Fine dusts of combustible material can present
Decreased filtration of ultraviolet radiation may an explosion hazard. Avoid explosive limits and
result in increases in skin cancer, cataracts and sources of ignition.
immune system suppression in humans, as well
as decreased productivity of crops and aquatic
systems. Electric Shock
CFCs are used primarily as refrigerants in vehicle Electric shock can result from the use of faulty
air conditioning systems and as aerosol electrical equipment or from the misuse of
propellants. Halons are used as fire equipment in good condition.
extinguishants. Make sure that electrical equipment is maintained
Ford supports worldwide elimination of CFC in good condition and frequently tested. Faulty
usage and it is recommended that Company equipment should be labelled and preferably
subsidiaries and affiliates should phase out CFC removed from the work station.
usage as soon as acceptable substitutes are Make sure that flexes, cables, plugs and sockets
commercially available. are not frayed, kinked, cut, cracked or otherwise
damaged.

Clutch Fluids Make sure that electrical equipment and flexes

do not come into contact with water.
See Brake fluids.
Make sure that electrical equipment is protected
by the correct rated fuse.
Clutch Linings and Pads Never misuse electrical equipment and never use
equipment which is in any way faulty. The results
See Asbestos.
could be fatal.
Make sure that the cables of mobile electrical
Corrosion Protection Materials equipment cannot get trapped and damaged,
such as in a vehicle hoist.
See also Solvents, Fire.
Make sure that the designated electrical workers
Highly flammable, flammable – observe No
are trained in basic First Aid.
Smoking policy.
In cases of electrocution:
These materials are varied and the
manufacturers instructions should be followed.
They may contain solvents, resins or petroleum
products. Skin and eye contact should be
avoided. They should only be sprayed in
conditions of adequate ventilation and not in
confined spaces.

Cutting
See Welding.

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DESCRIPTION AND OPERATION (Continued)

– switch off the power supply before Observe strict fire safety when storing and
approaching the victim. handling flammable materials or solvents,
– if this is not possible push or drag the victim particularly near electrical equipment or welding
from the source of electricity using dry non- processes.
conductive material. Make sure, before using electrical or welding
– commence resuscitation if trained to do so. equipment, that there is no fire hazard present.
– SUMMON MEDICAL ASSISTANCE. Have a suitable fire extinguisher available when
using welding or heating equipment.

Engine Oils
See Lubricants and Grease. First Aid
Apart from meeting any legal requirements it is
desirable for someone in the workshop to be
Exhaust Fumes trained in First Aid procedures.
These contain asphyxiating, harmful and toxic Splashes in the eye should be flushed carefully
chemicals and particles such as carbon oxides, with clean water for at least ten minutes.
nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should be run only under Soiled skin should be washed with soap and
conditions of adequate exhaust extraction or water.
general ventilation and not in confined spaces. In case of cold burns, from alternative fuels,
place affected area in cool to cold water.
Gasolene (petrol) engine Individuals affected by inhalation of gases and
fumes should be removed to fresh air
There may not be adequate warning of odour or immediately. If effects persist, consult a doctor.
of irritation before toxic or harmful effects arise.
These may be immediate or delayed. If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container
or label. Do not induce vomiting unless this action
Diesel engine is indicated on the label.
Soot, discomfort and irritation usually give
adequate warning of hazardous fume
concentrations. Fluoroelastomer
See Viton.
Fibre Insulation
See also Dusts. Foams - Polyurethane
Used in noise and sound insulation. See also Fire.
The fibrous nature of surfaces and cut edges can Used in sound and noise insulation. Cured foams
cause skin irritation. This is usually a physical used in seat and trim cushioning.
and not a chemical effect. Follow manufacturers instructions.
Precautions should be taken to avoid excessive Unreacted components are irritating and may be
skin contact through careful organization of work harmful to the skin and eyes. Wear gloves and
practices and the use of gloves. goggles.
Individuals with chronic respiratory diseases,
Fire asthma, bronchial medical problems, or histories
of allergic diseases should not work in or near
See also Welding, Foams, Legal Aspects. uncured materials.
Many of the materials found on or associated The components, vapours or spray mists can
with the repair of vehicles are highly flammable. cause direct irritation, sensitivity reactions and
Some give off toxic or harmful fumes if burnt. may be toxic or harmful.

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DESCRIPTION AND OPERATION (Continued)

Vapours and spray mists must not be inhaled. inhalation in the event of vapour build up arising
These materials must be applied with adequate from spillages in confined spaces.
ventilation and respiratory protection. Do not
Special precautions apply to cleaning and
remove the respirator immediately after spraying,
maintenance operations on gasolene storage
wait until the vapour/mists have cleared.
tanks.
Burning of the uncured components and the
Gasolene should not be used as a cleaning
cured foams can generate toxic and harmful
agent. It must not be siphoned by mouth. See
fumes. Smoking, naked flames or the use of
First Aid.
electrical equipment during foaming operations
and until vapours/mists have cleared should not
be allowed. Any heat cutting of cured foams or Gas-oil (Diesel Fuel)
partially cured foams should be conducted with
Combustible.
extraction ventilation. See also the vehicle Body
Repair Manual. Gross or prolonged skin contact with high boiling
point gas oils may also cause serious skin
disorders including skin cancer.
Freon
See Air Conditioning Refrigerant. Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning
agent.
Fuels
Flammable - observe No Smoking policy.
See also, Fire, Legal Aspects, Chemicals and
Solvents. Irritation of the mouth and throat may result from
swallowing. The main hazard from swallowing
Avoid skin contact with fuel where possible.
arises if liquid aspiration into the lungs occurs.
Should contact occur, wash the affected skin with
soap and water. Liquid contact dries the skin and can cause
irritation or dermatitis. Splashes in the eye may
be slightly irritating.
Gasoline (Petrol)
In normal circumstances the low volatility does
Highly flammable - observe No Smoking policy. not give rise to harmful vapours. Exposure to
Swallowing can result in mouth and throat mists and vapours from kerosene at elevated
irritation and absorption from the stomach can temperature should be avoided (mists may arise
result in drowsiness and unconsciousness. Small in dewaxing). Avoid skin and eye contact and
amounts can be fatal to children. Aspiration of make sure there is adequate ventilation.
liquid into the lungs, through vomiting, is a very
serious hazard. Alternative Fuel
Gasolene dries the skin and can cause irritation
Highly flammable. Observe ``NO SMOKING"
and dermatitis on prolonged or repeated contact.
signs.
Liquid in the eye causes severe smarting.
Make sure there is adequate ventilation when
Motor gasolene may contain appreciable
working on alternative fuelled vehicles. Great
quantities of benzene, which is toxic upon
care must be taken to avoid the serious
inhalation, and the concentration of gasolene
consequences of inhalation in the event of
vapours must be kept very low. High
vapour build up in confined spaces.
concentrations will cause eye, nose and throat
irritation, nausea, headache, depression and Inhalation in high concentrations may cause
symptoms of drunkenness. Very high dizziness, headache, nausea and loss of co-
concentrations will result in rapid loss of ordination. Very high concentrations may result in
consciousness. loss of consciousness.
Make sure there is adequate ventilation when Contact with liquidified petroleum gas (LPG) or
handling and using gasolene. Great care must be compressed natural gas (CNG) to skin may
taken to avoid the serious consequences of cause cold burns and may cause frost bite.

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DESCRIPTION AND OPERATION (Continued)

Long sleeved cotton overalls, steel toe capped General Workshop Tools and Equipment
safety boots and rubber neoprene gloves should
It is essential that all tools and equipment are
be worn during removal and installation of
maintained in good condition and the correct
LPG/CNG fuel system components.
safety equipment is used where required.
LPG/CNG fuel leaks could cause a fire and be a
Never use tools or equipment for any purpose
hazard to health that can lead to personal injury,
other than that for which they were designed.
illness or even death.
Never overload equipment such as hoists, jacks,
If a leak is detected, under no circumstances axle and chassis stands or lifting slings. Damage
attempt to seal the leak by tightening the caused by overloading is not always immediately
union/connection until the fuel in the system or apparent and may result in a fatal failure the next
component is depressurised. Once tightened the time that the equipment is used.
system should be checked for integrity following
Do not use damaged or defective tools or
the specified procedures.
equipment, particularly high speed equipment
If the fuel tank is to be removed for service or such as grinding wheels. A damaged grinding
repair the fuel must be evacuated using wheel can disintegrate without warning and
dedicated equipment and following the specified cause serious injury.
procedures.
Wear suitable eye protection when using
grinding, chiselling or sand blasting equipment.
Gas Cylinders Wear a suitable breathing mask when using
abrasive blasting equipment, working with
See also Fire. asbestos-based materials or using spraying
Gases such as oxygen, acetylene, argon and equipment.
propane are normally stored in cylinders at Make sure there is adequate ventilation to control
pressures of up to 138 bar (2000 psi) and great dusts, mists and fumes.
care should be taken in handling these cylinders
to avoid mechanical damage to them or to the
valve gear attached. The contents of each
High Pressure Air, Lubrication and Oil Test
cylinder should be clearly identified by
Equipment
appropriate markings.
See also Lubricants and Greases.
Cylinders should be stored in well ventilated
enclosures, and protected from ice and snow, or Always keep high pressure equipment in good
direct sunlight. Fuel gases, for example acetylene condition, and regularly maintained, particularly
and propane, should not be stored in close at joints and unions.
proximity to oxygen cylinders. Never direct a high pressure nozzle, for example
Care should be exercised to prevent leaks from diesel injector, at the skin as the fluid may
gas cylinders and lines, and to avoid sources of penetrate to the underlying tissue, and cause
ignition. serious injury.
Only trained personnel should undertake work
involving gas cylinders.
Halon
See CFCs.
Gases
See Gas Cylinders.
Legal Aspects
There are many laws and regulations relating to
Gaskets (Fluoroelastomer) health and safety in the use and disposal of
materials and equipment in a workshop.
See Viton.
For a safe working environment and to avoid
environmental pollution, workshops should be
familiar, in detail, with the many health and safety

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DESCRIPTION AND OPERATION (Continued)

laws and regulations within their country, Health Protection Precautions

published by both national and local authorities.
– Avoid prolonged and repeated contact with
oils, particularly used engine oils.
Lubricants and Greases – Wear protective clothing, including impervious
gloves where practicable.
Avoid all prolonged and repeated contact with – Do not put oily rags into pockets.
mineral oils. All lubricants and greases may be
irritating to the eyes and skin. – Avoid contaminating clothes, particularly
underpants, with oil.
– Heavily soiled clothing and oil-impregnated
Used Engine Oil footwear should not be worn. Overalls must
Prolonged and repeated contact with mineral oil be cleaned regularly.
will result in the removal of natural fats from the – First Aid treatment should be obtained
skin, leading to dryness, irritation and dermatitis. immediately for open cuts and wounds.
In addition, used engine oil contains potentially – Use barrier creams, applying them before
harmful contaminants which may cause skin each work period, to help the removal of oil
cancer. Adequate means of skin protection and from the skin.
washing facilities must be provided.
– Wash with soap and water to make sure all oil
Do not employ used engine oils as lubricants or is removed (skin cleansers and nail brushes
for any application where appreciable skin will help). Preparations containing lanoline
contact is likely to occur. replace the natural skin oils which have been
removed.
– Do not use gasolene (petrol), kerosene
(paraffin), diesel fuel (gas oil), thinners or
solvents for cleaning skin.
– If skin disorders develop, obtain medical
advice without delay.
– Where practicable, degrease components
prior to handling.
– Where there is a risk of eye contact, eye
protection should be worn, for example
chemical goggles or face shields; in addition
an eye wash facility should be provided.

Environmental Precautions
Burning used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensed
waste disposal sites, or to the waste oil
reclamation trade. If in doubt, contact the relevant
local authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground,
down sewers or drains, or into water courses.

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DESCRIPTION AND OPERATION (Continued)

Noise application does not normally give rise to toxic
lead fumes, provided a gas/air flame is used.
Some operations may produce high noise levels
Oxy-acetylene flames should not be used, as
which could, in time, damage hearing. In these
they are much hotter and will cause lead fumes
cases, suitable ear protection must be worn.
to be produced.
Some fumes may be produced by the application
Noise Insulation Materials of any flame to surfaces coated with grease, and
inhalation of these should be avoided.
See Foams, Fibre Insulation.
Removal of excess solder should be undertaken
with care, to make sure that fine lead dust is not
O-Rings (Fluoroelastomer) produced, which can give toxic effects if inhaled.
Respiratory protection may be necessary.
See Viton.
Solder spillage and filings should be collected
and removed promptly to prevent general air
Paints contamination by lead.
See also Solvents, Chemical Materials. High standards of personal hygiene are
necessary in order to avoid ingestion of lead or
Highly flammable, flammable - observe No inhalation of solder dust from clothing.
Smoking policy

One Pack Solvents

Can contain harmful or toxic pigments, driers and See also Chemical Materials, Fuels (Kerosene),
other components as well as solvents. Spraying Fire.
should be carried out only with adequate For example acetone, white spirit, toluene,
ventilation. xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints,
Two Pack plastics, resins and thinners.
Can also contain harmful and toxic unreacted Some may be highly flammable or flammable.
resins and resin hardening agents. The Skin contact will degrease the skin and may
manufacturers instructions should be followed.
result in irritation and dermatitis following
See also Resin-based Adhesives and Isocyanate
repeated or prolonged contact. Some can be
Adhesives and Sealers under Adhesives and
absorbed through the skin in toxic or harmful
Sealers.
quantities.
Spraying should preferably be carried out in Splashes in the eye may cause severe irritation
exhausted ventilated booths removing vapour and could lead to loss of vision.
and spray mists from the breathing zone.
Individuals working in booths should wear Brief exposure of high concentrations of vapours
appropriate respiratory protection. Those doing or mists will cause eye and throat irritation,
small scale repair work in the open workshop drowsiness, dizziness, headaches and, in the
should wear air-fed respirators. worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive
but lower concentrations of vapours or mists, for
Pressurized Equipment which there might not be adequate warning
See High Pressure Air, Lubrication and Oil Test indications, can cause more serious toxic or
Equipment. harmful effects.
Aspiration into the lungs, for example through
vomiting, is the most serious consequence of
Solder swallowing.
Solders are mixtures of metals such that the Avoid splashes to the skin, eyes and clothing.
melting point of the mixture is below that of the Wear protective gloves, goggles and clothing if
constituent metals (normally lead and tin). Solder necessary.
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DESCRIPTION AND OPERATION (Continued)

Make sure there is good ventilation when in use, they are exposed to temperatures in excess of
avoid breathing fumes, vapours and spray mists 400°C, the material will not burn, but will
and keep containers tightly sealed. Do not use in decompose, and one of the products formed is
confined spaces. hydrofluoric acid.
When spraying materials containing solvents, for This acid is extremely corrosive and may be
example paints, adhesive, coatings, use absorbed directly, through contact, into the
extraction ventilation or personal respiratory general body system.
protection in the absence of adequate general
O-rings, seals or gaskets which have been
ventilation.
exposed to very high temperatures will appear
Do not apply heat or flame except under specific charred or as a black sticky substance.
and detailed manufacturers instructions.
DO NOT, under any circumstances touch them or
the attached components.
Sound Insulation Enquiries should be made to determine whether
Viton or any other fluoroelastomer has been used
See Fibre Insulation, Foams. in the affected O-ring, seal or gasket. If they are
of natural rubber or nitrile there is no hazard. If in
doubt, be cautious as the material may be Viton
Suspended Loads or any fluoroelastomer.
CAUTION: Never improvise lifting tackle. If Viton or any other fluoroelastomers have been
There is always a danger when loads are lifted or used, the affected area should be
suspended. Never work under an unsupported, decontaminated before the commencement of
suspended or raised load, for example a work.
suspended engine. Disposable heavy duty plastic gloves should be
Always make sure that lifting equipment such as worn at all times, and the affected area washed
jacks, hoists, axle stands and slings are down using wire wool and a limewater (calcium
adequate and suitable for the job, in good hydroxide) solution to neutralise the acid before
condition and regularly maintained. disposing of the decomposed Viton residue and
final cleaning of the area. After use, the plastic
gloves should be discarded carefully and safely.
Transmission Brake Bands
See Asbestos. Welding
See also Fire, Electric Shock, Gas Cylinders.
Underseal Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
See Corrosion Protection.

Resistance Welding
Viton
This process may cause particles of molten metal
In common with many other manufacturers to be emitted at a high velocity, and the eyes and
vehicles, some components fitted to the Ford skin must be protected.
range have O-rings, seals or gaskets which
contain a material known as `Viton'.
Arc Welding
Viton is a fluoroelastomer, that is a synthetic
rubber type which contains Fluorine. It is This process emits a high level of ultra-violet
commonly used for O-rings, gaskets and seals of radiation which may cause arc-eye and skin
all types. Although Viton is the most well known burns to the operator and to other persons
fluoroelastomer, there are others, including nearby. Gas-shielded welding processes are
Fluorel and Tecmoflon. particularly hazardous in this respect. Personal
protection must be worn, and screens used to
When used under design conditions shield other people.
fluoroelastomers are perfectly safe. If, however,

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DESCRIPTION AND OPERATION (Continued)

CONTACT LENS WEARERS ARE ADVISED TO Warning Symbols on Vehicles
REVERT TO ORDINARY SPECTACLES WHEN
Decals showing warning symbols will be found on
ARC WELDING as the arc spectrum is believed
various vehicle components.
to emit microwaves which dry out the fluid
between the lens and the eye. This may result in These decals must not be removed. The
blindness when the lens is removed from the eye. warnings are for the attention of
owners/operators and persons carrying out
Metal spatter will also occur, and appropriate eye
service or repair operations on the vehicle.
and skin protection is necessary.
The most commonly found decals are
The heat of the welding arc will produce fumes
reproduced below together with an explanation of
and gases from the metals being welded, the
the warnings.
rods and from any applied coatings or
contamination on the surfaces being worked on.
These gases and fumes may be toxic and
inhalation of these should be avoided. The use of
extraction ventilation to remove the fumes from
the working area may be necessary particularly in
cases where the general ventilation is poor, or
where considerable welding work is anticipated.
In extreme cases or confined spaces where
adequate ventilation cannot be provided, air-fed
respirators may be necessary.

Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding
and cutting, and special care must be taken to 1. Components or assemblies displaying the
prevent leakage of these gases, with consequent caution triangle and open book symbol
risk of fire and explosion. advise consultation of the relevant section of
the owners handbook before touching or
The process will produce metal spatter and eye attempting adjustments of any kind.
and skin protection is necessary.
The flame is bright, and eye protection should be
used, but the ultra-violet emission is much less
than that from arc welding, and lighter filters may
be used.
The process itself produces few toxic fumes, but
such fumes and gases may be produced from
coatings on the work, particularly during cutting
away of damaged body parts, and inhalation of
the fumes should be avoided.
In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard
may arise if brazing rods containing cadmium are
used. In this event particular care must be taken
to avoid inhalation of fumes and expert advice
may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN
BEFORE ANY WELDING OR CUTTING TAKES
PLACE ON VESSELS WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, FOR
EXAMPLE BOILING OR STEAMING OUT OF
FUEL TANKS.

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DESCRIPTION AND OPERATION (Continued)

2. Components or assemblies displaying the 5. Displaying the caution circle with a deleted
warning triangle with the `electrified' arrow lighted match symbol, caution against the
and open book symbol give warning of use of naked lights or flames within the
inherent high voltages. Never touch these immediate vicinity due to the presence of
with the engine running or the ignition highly flammable or explosive liquids or
switched on. See Electric Shock in this vapours. See Fire in this subsection.
subsection.

6. Displaying this symbol (normally in

3. Ford vehicles and replacement parts which conjunction with 5 above) warn of the
contain asbestos are identified by this presence of potentially explosive matter
symbol. See Asbestos in this subsection. within the immediate vicinity.

4. Components or assemblies displaying this 7. Displaying this symbol warn that children
symbol give warning that the component should not be allowed in the immediate
contains a corrosive substance. See Acids vicinity unsupervised.
and Alkalis in this subsection.

White Spirit
See Solvents.

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DESCRIPTION AND OPERATION

Standard Workshop Practices

– extinguish all flames and lighted tobacco.

– shut off electrical and air powered equipment.
– evacuate the area.
Vehicle in Workshop
– ventilate the area.
When working on a vehicle in the workshop – contact fire control authorities.
always make sure that:
– remove the vehicle to a dedicated, ventilated
– the parking brake is applied or the wheels are area.
securely chocked to prevent the vehicle
moving forwards or backwards.
– the key is removed from key operated hood Alternative Fuel — Do's
locks before any work is carried out around
– do work on the vehicle in a designated area
the front of the vehicle.
that is well ventilated and its access restricted
– if the engine is to be run, there is adequate to qualified personnel only
ventilation, or an extraction hose to remove
– install new warning labels to their original
exhaust fumes.
locations
– there is adequate room to raise the vehicle
– if possible always isolate the alternative fuel
and remove the wheels, if necessary.
tank, run the vehicle on the alternative fuel
– fender covers are always fitted if any work is until it automatically switches to its normal
to be carried out in the engine compartment. fuel prior to taking the vehicle into the
– the battery is disconnected if working on the workshop/service area
engine, underneath the vehicle, or if the – only use tested and approved components
vehicle is raised. and pipes when repairing or servicing LPG
and CNG systems
CAUTION: When electric arc welding on a
vehicle, always disconnect the generator
wiring to prevent the possibility of a
surge of current causing damage to the Alternative Fuel — Do Nots
internal components of the generator. – do not vent off LPG fuel
– If using welding equipment on the vehicle, a – do not use shop air pressure to force LPG
suitable fire extinguisher is readily available. fuel from the fuel tank
– do not use paint drying ovens above 40°C for
any alternative fuel vehicles. LPG and CNG
Alternative Fuel fuel tanks should be removed from the
vehicles prior to being put into paint drying
WARNING: When servicing the fuel
ovens above 40°C
system always follow the recommended
procedures. Failure to follow these – do not modify the system or install new
instructions may result in personal components with parts not designed for gas
injury. vehicles
– do not evacuate fuel tanks unless there is
If the odour of liquified petroleum gas (LPG) or
repair that requires removed of the fuel tank
compressed natural gas (CNG) is present in the
air in the workshop, warn all persons in the area – do not work on the fuel lines or system
to: components unless the alternative fuel has
been evacuated and the pressure in the
system is reduced to atmospheric, or less
– do not use anything other than the specified
leak detector fluid to trace fuel leaks
Be aware of situations that may cause the LPG
or CNG fuel system to vent off fuel, such as:

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DESCRIPTION AND OPERATION (Continued)

– extremely hot days

– parking by a space heater
CAUTION: A discharged battery
– hoisting a vehicle up near a ceiling heater condition may have been caused by an
Only personnel fully trained to Ford and local electrical short circuit. If this condition
standards are to work on alternative fuel vehicles. exists there will be an apparently live
circuit on the vehicle even when all
normal circuits are switched off. This can
Towing the Vehicle cause arcing when the jumper cables are
connected.
WARNING: When the vehicle is being
towed the ignition switch must be in CAUTION: While it is not recommended
position II (steering lock released and that the vehicle is jump started, it is
warning lights illuminated). Only then recognized that this may occasionally be
will the steering, turn signal lamps, horn the only practical way to mobilize a
and stop lamps be operational. Failure to vehicle. In such an instance the
follow these instructions may result in discharged battery must be recharged
personal injury. immediately after jump starting to avoid
permanent damage.
NOTE: The removable towing eye (if equipped)
has a left-hand thread and must be fully tightened – Always make sure that the jumper cables are
before towing can commence. adequate for the task. Heavy duty cables
must be used.
When towing is necessary, the vehicle towing
– Always make sure that the slave battery is of
eyes should be used. The rope must be securely
the same voltage as the vehicle battery. The
fastened to the towing eyes and must also be
batteries must be connected in parallel.
attached to the other vehicle such that the rope
will not foul the bodywork. – Always make sure that switchable electric
circuits are switched off before connecting
When a vehicle with automatic transmission is jumper cables. This reduces the risk of arcing
towed, the gear selector must be in position N occurring when the final connection is made.
(Neutral). Never tow a vehicle with automatic
transmission faster than 30 mph (50 km/h) or
further than 30 miles (50 km). If it is necessary to
tow the vehicle a greater distance, the drive
wheels must be lifted clear off the ground.
Alternatively the vehicle can be transported on a
low loader or a trailer.

Connecting a Slave Battery Using Jumper

Cables
WARNING: If the slave battery has
recently been charged and is gassing,
cover the vent plugs or covers with a WARNING: Make sure that the ends of
damp cloth to reduce the risk of the jumper cables do not touch each
explosion should arcing occur when other or ground against the vehicle body
connecting the jumper cables. Failure to at any time while the cables are attached
follow these instructions may result in to the battery. A fully charged battery, if
personal injury. shorted through jumper cables, can
discharge at a rate well above 1000 amps
causing violent arcing and very rapid
heating of the jumper cables and
terminals, and can even cause the
battery to explode. Failure to follow
these instructions may result in personal
injury.

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DESCRIPTION AND OPERATION (Continued)

Always connect the jumper cables in the – blowing dirt off with compressed air. (Eye
following sequence: protection must be worn when using this
method)
– slave battery positive first then vehicle battery
positive – removal of dry dust using vacuum equipment.
This method should always be used to
– slave battery negative next and then vehicle
remove friction lining material dust (asbestos
ground at least 12 inches (300 mm) from the
particles)
battery terminal, for example engine lifting
eye – steam cleaning
Always reduce the engine speed to idle before WARNING: Most solvents require careful
disconnecting the jumper cables. handling and some are harmful. Refer to
Before removing the jumper cables from the Health and Safety Precautions and to the
vehicle that had the discharged battery, switch on manufacturers literature for safety
the heater blower (high) or the heated rear precautions. Failure to follow these
window, to reduce the voltage peak when the instructions may result in personal
cables are removed. injury.

Always disconnect the jumper cables in the Various solvents are available which are suitable
reverse order to the connecting sequence and do for component cleaning. Some components such
not short the ends of the cables. as brake hydraulic parts and electrical
assemblies should be cleaned only with
Do not rely on the generator to restore a recommended solvents — refer to Solvents,
discharged battery. For a generator to recharge a Sealers and Adhesives or to the section of the
battery, it would take in excess of eight hours manual relevant to the component.
continuous driving with no additional loads placed
on the battery.
Calibration of Essential Measuring Equipment

Component Cleaning WARNING: Failure to follow these

instructions may result in personal injury
To prevent ingress of dirt, accumulations of loose or damage to components.
dirt and greasy deposits should be removed
before disconnecting or dismantling components It is of fundamental importance that certain
or assemblies. essential equipment, for example torque
wrenches, multimeters, exhaust gas analysers or
Components should be thoroughly cleaned rolling roads, are regularly calibrated in
before inspection prior to reassembly. accordance with the manufacturers instructions.

Cleaning Methods:
– dry cleaning
– removal of loose dirt with soft or cable
brushes
– scraping dirt off with a piece of metal or wood
– wiping off with a rag
CAUTION: Compressed air is sometimes
'wet' so use with caution, especially on
hydraulic systems.

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DESCRIPTION AND OPERATION

Solvents, Sealers and Adhesives

CAUTION: If in doubt about the suitability

Introduction of any proprietary solvent or sealer for a
particular application, contact the
WARNING: Always handle all solvents, manufacturer of the product for
sealers and adhesives with extreme care. information regarding storage, handling
Some contain chemicals or give off and application.
fumes which can be dangerous to health. The Health and Safety Precautions subsection
Always follow the manufacturers refers to some commonly used chemicals and
instructions. If in doubt about any materials, hazards associated with their use, and
substance, particularly a solvent, DO safety measures to be taken. Some of these
NOT use it. chemicals may be included in the following list
either in their own right or as an ingredient in a
sealer or adhesive.
General Specifications

Anti-Seize Compound
ROCOL KS PAUL
General SAM-1C-9107A Foliac J166 PBC or PBC
SAM-1C-9107A KluberUnimoly 492 TAC 2
Spark plug ESE-M1244-A `Never-Seize' Catalogue No. NSBT-8N, 227g; Catalogue No. NSN
threads obtainable through Snap-on Tools Limited, 165 from local Bostic
Palmer House, 150/154 Cross Street, Sale, supplier.
Cheshire. M33 1AQ

Sealers
Manufacturer and
Application Ford Spec. Identification
For camshaft bearing caps ESK-M4G260-A Loctite 518
For cylinder block WSK-M4G320-A Hylosil 502
For fitting rear lamp assembly WSK-M4G329-ABC
For transmission housing (80 gram can) Finis Code 6 160 443

Adhesives
Application Ford Spec.
PU for windscreen, side and rear glass Finis Code 6 997 259

G17374 en 08/2002 2003.0 Mondeo

100-00-22 General Information 100-00-22

DESCRIPTION AND OPERATION

Road/Roller Testing

Road or roller testing may be carried out for With the ignition switched off, check:
various reasons and a procedure detailing pre-
– The handbrake is applied.
test checks, through engine starting and
stopping, pre-driving checks, on-test checks to – The gear lever is in neutral.
final checks on completion of the test is given – All instrument gauges (except fuel gauge)
overleaf. read zero.
Unless complete vehicle performance is being With the ignition switched on, check:
checked, the full road test procedure need not be – Ignition controlled warning lights come on.
carried out. Instead, those items particularly
relevant to the system/s being checked can be – Engine temperature gauge registers a
extracted. reading compatible with the engine
temperature.
– Fuel gauge registers a reading appropriate to
Pre-Test Checks the fuel level in the tank.
– The operation of the handbrake warning light
WARNING: If the brake system hydraulic and fluid level warning indicator light.
fluid level is low, pedal travel is
excessive or a hydraulic leak is found,
do not attempt to road test the vehicle On Road or Roller Test Check:
until the reason for the low fluid level,
excessive pedal travel or hydraulic leak CAUTION: If road testing, check the
is found and rectified. brake operation while still travelling at
It is suggested that pre-test checks, and low speed before continuing with the
functional tests of those systems/circuits which test. If the brakes pull to one side, or
affect the safe and legal operations of the appear to be otherwise faulty, do not
vehicle, such as brakes, lights and steering, continue with the road test until the fault
should always be carried out before the road or has been found and rectified.
roller test.
– Engine oil level
– Engine coolant level
– Tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
– There is sufficient fuel in the tank to complete
the test.
– All around the engine, transmission and
under the vehicle for oil, coolant, hydraulic
and fuel leaks. Make a note of any apparent
leaks and wipe off the surrounding areas to
make it easier to identify the extent of the leak
on completion of the test.

Starting the Engine

NOTE: On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h
(15 miles/h). Never operate at high engine speed
or with the accelerator pedal at full travel whilst
the engine is cold.

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100-00-23 General Information 100-00-23

DESCRIPTION AND OPERATION (Continued)

– Clutch pedal operation is not stiff or heavy.

CAUTION: Brake testing which includes
– Initial gear engagement is smooth and there heavy brake applications should not be
is no evidence of clutch drag. carried out with new brake pads/discs or
– Handbrake control operates smoothly and the linings/drums until the components have
handbrake releases quickly and completely. bedded-in. New brake friction
– Clutch takes up the drive smoothly, without components will not reach full efficiency
slip or judder. until the bedding-in process is complete.
– Gear changing is smooth, and there are no Test the brakes at several speeds within the
abnormal noises or vibrations from the normal operating range using both light and
transmission. heavy pedal pressure. Note any tendency to
– The engine power output is satisfactory, full snatch, pull or drag, and any undue delay in
power is achieved, acceleration is smooth application or release.
and pedal operation not stiff or heavy, and Allow the vehicle to coast and note any tendency
engine speed returns to idle correctly. to pull to one side, or evidence that the brakes
– There is no excessive or abnormally colored are binding.
smoke from the engine under normal driving,
After stopping the vehicle (not immediately after a
heavy load or overrun conditions.
period of heavy braking), carefully check the
– Steering operation, including power steering brake temperature. A disc which feels hot, or
where fitted, is smooth, accurate, not appreciably hotter than the others, indicates that
excessively heavy or with excessive free play the brake is binding.
or vibration. Does not pull to one side and self
centres smoothly after cornering. After completion of the test, check for:
– Speedometer, oil pressure warning lamp, – Oil, coolant, hydraulic, air and fuel leaks.
coolant temperature gauge and tachometer – Abnormal temperature of any moving
(where fitted) register the correct readings or components or assemblies, e.g. wheel hubs,
operate correctly. transmission, axle etc., which might indicate
– Switches and controls operate smoothly and overtightness or lack of lubrication.
positively, warning or indicator lights operate
correctly and the direction indicator control
self cancels when the steering is returned to
the straight ahead position.
– Heating and ventilation systems work
correctly and effectively.
– Brake operation and efficiency.

Brake Testing
WARNING: When brake testing, avoid
breathing the smoke or fumes from hot
brakes, this may contain asbestos dust
which is hazardous to health, see Health
and Safety Precautions.
Avoid brake testing on busy roads where it can
cause inconvenience or danger to other road
users.

G17375 en 08/2002 2003.0 Mondeo

100-01-1 Identification Codes 100-01-1

SECTION 100-01 Identification Codes

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Identification Codes ........................................................................................................... 100-01-2

Vehicle Identification Number ........................................................................................... 100-01-3
Vehicle Certification Label (Typical) or VIN Plate.............................................................. 100-01-4

08/2002 2003.0 Mondeo

100-01-2 Identification Codes 100-01-2

DESCRIPTION AND OPERATION

Identification Codes
DESCRIPTION AND OPERATION

established. The vehicle identification number

The vehicle identification plate is located on the
(VIN) may also be checked through the
right-hand B-pillar. The codes stamped on the
windshield, or on the bulkhead under the hood,
plate during production enable the precise details
where it is stamped onto the body.
of the vehicle build specification to be

Item Part Description

Item Part Description Number
Number
2 – VIN on the bulkhead
1 – Visible VIN
3 – Vehicle identification plate

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100-01-3 Identification Codes 100-01-3

DESCRIPTION AND OPERATION

Vehicle Identification Number

Item Part Description

Item Part Description Number
Number
5 - VIN Position 11 — Year of
1 - VIN Position 1, 2 and 3 — manufacture
World manufacturer identifier
6 - VIN Position 12 — Month of
2 - VIN Position 5 and 6 — manufacture
Constant X
7 - VIN Position 13 to 17 — Ve-
3 - VIN Position 7 and 8 — hicle serial number
Product source company
and assembly plant 8 - VIN Position 4 and 10 —
Body type
4 - VIN Position 9 — Model

VIN Position 1, 2 and 3 — World Manufacturer Identifier

Codes World Manufacturer
WF0 Ford Werke AG Germany (European vehicles)
WF1 Ford Werke A.G. Germany (Federal vehicles)

VIN Position 4 and 10 — Model Variants

Code Model Variant
W Wagon
4 4-door

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100-01-4 Identification Codes 100-01-4

DESCRIPTION AND OPERATION (Continued)

Code Model Variant
5 5-door
VIN Positions 5 and 6 — Constant X

VIN Position 7 and 8 — Product Source Company and Assembly Plant

Code Product Source Company and Assembly Plant
GA Ford of Germany/Cologne
GB Ford of Germany/Genk

VIN Position 9 — Model Range

Code Model Range
B Mondeo

VIN Position 11 — Year of Manufacture

Code Year of Manufacture
Y 2000
1 2001
2 2002
3 2003
4 2004
5 2005

VIN Position 12 — Month of Manufacture

Month 2000 2001 2002 2003 2004 2005
January B J L C B J
February R U Y K R U
March A M S D A M
April G P T E G P
May C B J L C B
June K R U Y K R
July D A M S D A
August E G P T E G
September L C B J L C
October Y K R U Y K
November S D A M S D
December T E G P T E
VIN Position 13 to 17 — Vehicle Serial Number
Five Digit Number
Vehicle Certification Label (Typical) or VIN
Plate

G37346 en 08/2002 2003.0 Mondeo

100-01-5 Identification Codes 100-01-5

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
8 - Variants
1 - Type approval codes
9 - Type
2 - Vehicle identification number
(VIN) 10 - Emission level codes

3 - Gross vehicle mass (GVM) 11 - Body color codes

4 - Gross train mass (GTM) 12 - Interior trim codes

5 - Maximum permissible front 13 - Transaxle final drive ratio

axle mass 14 - Transaxle codes
6 - Maximum permissible rear 15 - Engine codes
axle mass
16 - Hand of drive
7 - Smoke value (diesel only)

Item 1 to 6: Vehicle Certification Label

Item Details
Item 1: Type Approval Codes A unique code required by legislation in certain ter-
ritories.
Item 2: Vehicle Identification Number (VIN) Vehicle identification number.
Item 3: Gross Vehicle Mass Indicates maximum legal laden mass, in territories
where this is required.

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100-01-6 Identification Codes 100-01-6

DESCRIPTION AND OPERATION (Continued)

Item Details
Item 4: Gross Train Mass Indicates the maximum combined mass of vehicle
and trailer or caravan.
Item 5: Maximum Permissible Front Axle Mass Maximum permissible loading on the front wheels
of the vehicle.
Item 6: Maximum Permissible Rear Axle Mass Maximum permissible loading on the rear wheels
of the vehicle.

Item 7: Smoke Value (Diesel only)

Code Smoke value
— —
— —
— —

Item 8 and 9: Variants

Code Variant
B4Y 4-door
B5Y 5-door
BWY Wagon

Item 10: Emission Level Codes

Code Exhaust Emissions
E 1504 requirements
L Mexico requirements
S 2000 EEC
7 Stage IV requirements

Item 11: Body Color Codes

Code Body Color
A Nantucket Grey
B Diamond White
C Colorado Red
D Dark True Blue
F Aquamarine Frost Pearl
G Panther Black
K State Blue
M Magnum Grey
N Neptune Green
P Spruce Green Pearl
Q Metropolis Blue
R Infra Red
S Oyster Silver
T Medium Harvest Gold
1 Pepper Red
2 Medium Steele Blue
3 Juice Green
4 Spruce Green
5 Amparo Blue Metallic
6 Stardust Silver

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100-01-7 Identification Codes 100-01-7

DESCRIPTION AND OPERATION

For vehicles built in UK plants, the second digit of the

For vehicles built in continental plants, the second digit
vehicle paint code, on the VIN label, denotes the
of the paint code, on the VIN label, denotes the
current model year, ('0' = built in 2000 model year).
original model year of the color's introduction, ('0' =
color introduction in 2000 model year).

Item 12: Interior Trim Codes

Code Interior Trim
EB Baskey - Ebony
EL Leather - Ebony
GB Basket — Light Graphite
GL Leather - Light Graphite
IL Leather - Infra Red
MM Mars — Midnight Blue
NL Leather — Non/Color
NN Zeuz — Non Color
PB Basket — Light Parchment
PL Leather — Light Parchment
PM Mars — Light Parchment
RZ Zeus — Radiant Red
SZ Zeuz — State Blue

Item 13: Transaxle Final Drive Ratio

Code Transaxle Final Drive Ratio
3 4.06
4 3.82
5 4.23
7 3.41
8 3.56
9 3.92

Item 14: Transaxle Codes

Code Transaxle
A CVT automatic ZFI Ford
F 6-speed manual transmission MMT6
H 5-speed manual transaxle MTX75 high torque
Q 5-speed manual transaxle MTX75
T 5-speed automatic - jatco select shift
6 4-speed automatic CD4E

Item 15: Engine Codes

Code Engine
F Mazda 1.8L DOHC SCV 14
G Mazda 1.8L DOHC SFI 110 PS
H Mazda 1.8L DOHC SFI 125 PS
J Mazda 2.0L DOHC SCV 14
M 2.0L I4 160 PS
S Duratec 2.5L DOHC V6
U 3.0L Duratec OHC V6 220 PS
5 Puma 2.0L TCI 90 PS Diesel
6 Puma 2.0L TCI 115 PS Diesel
7 Puma 2.0L HPCR 115 PS Diesel
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100-01-8 Identification Codes 100-01-8

DESCRIPTION AND OPERATION (Continued)

Code Engine
8 Puma 2.0L OHC TC 130 PS Diesel

Item 16: Hand of Drive

Code Drive
1 Left-hand drive
2 Right-hand drive
3 Left-hand drive
4 Right-hand drive
5 Left-hand drive
6 Right-hand drive
7 Left-hand drive
8 Right-hand drive

G37346 en 08/2002 2003.0 Mondeo

100-02-1 Jacking and Lifting 100-02-1

SECTION 100-02 Jacking and Lifting

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Jacking .............................................................................................................................. 100-02-2

Lifting................................................................................................................................. 100-02-3

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100-02-2 Jacking and Lifting 100-02-2

DESCRIPTION AND OPERATION

Jacking
DESCRIPTION AND OPERATION

WARNING: Always position the vehicle CAUTION: It is important that only the
on a hard level surface. If the vehicle correct jacking and support locations are
must be jacked up on a soft surface use used at all times.
load spreading blocks under the jack.
Always chock the wheel diagonally
opposite the jacking point. Failure to
follow these instructions may result in
personal injury.

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100-02-3 Jacking and Lifting 100-02-3

DESCRIPTION AND OPERATION

Lifting

CAUTION: When lifting a vehicle with a CAUTION: It is important that only the
two-post lift, vehicle leveling pads must correct lifting and support locations are
be used under the lifting points. used at all times.

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100-04-1 Noise, Vibration and Harshness 100-04-1

SECTION 100-04 Noise, Vibration and Harshness

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH).............................................................................. 100-04-2

Inspection and Verification ............................................................................................... 100-04-2
How to Use this Diagnostic Procedure Section................................................................. 100-04-2
Customer interview........................................................................................................... 100-04-2
Identify the Condition........................................................................................................ 100-04-2
Noise Diagnostic Procedure ............................................................................................. 100-04-2
Road Test......................................................................................................................... 100-04-3
Road Test Quick Checks.................................................................................................. 100-04-4
Road Conditions............................................................................................................... 100-04-4
Vehicle Preparation .......................................................................................................... 100-04-5
Symptom Chart ................................................................................................................ 100-04-5
Pinpoint Tests .................................................................................................................. 100-04-5

GENERAL PROCEDURES

Exhaust System Neutralizing ........................................................................ (25 001 0) 100-04-10

08/2002 2003.0 Mondeo

100-04-2 Noise, Vibration and Harshness 100-04-2

DIAGNOSIS AND TESTING

Noise, Vibration and Harshness (NVH)

DIAGNOSIS AND TESTING

identify the concern and will provide direction to

the correct starting point for diagnosis.
Inspection and Verification
1. Verify the customer concern.
Identify the Condition
2. Visually inspect for obvious signs of
mechanical or electrical damage. NVH usually occur in four areas:
3. If an obvious cause for an observed or • tires
reported concern is found, correct the cause • engine accessories
(if possible) before proceeding to the next • suspension
step.
• driveline
4. If the concern is not visually evident, verify
the symptom and refer to the Symptom It is important, therefore, that an NVH concern be
Chart. isolated into its specific area(s) as soon as
possible. The easiest and quickest way to do this
is to carry out the Road Test as outlined. To
How to Use this Diagnostic Procedure assist in the diagnosis and testing procedure(s),
Section use a suitable approved NVH diagnosis tester.
• Noise, vibration and harshness (NVH)
concerns have become more important as Noise Diagnostic Procedure
vehicles have become more sensitive to
these vibrations. This section is designed to
aid in identifying these concerns. Non-Axle Noise
• The section provides diagnostic procedures The five most common sources of non-axle noise
based on symptom. If the condition occurs at are exhaust, tires, roof racks, trim panels and
high speed, for instance, the most likely place transmission.
to start is under Shake and Vibration While
Driving. Therefore, make sure that none of the following
conditions are the cause of the noise before
• The road test procedure will tell how to sort
proceeding with a driveline teardown and
the conditions into categories and how to tell
diagnosis.
a vibration from a shake.
• A series of Road Test Quick Checks are
provided to make sure that a cause is either
pinpointed or eliminated.
• Name the condition, proceed to the
appropriate section and locate the correct
diagnosis. When the condition is identified,
the job is partly done.
• Follow the diagnostic procedure as outlined.
• Quick Checks are described within the step,
while more involved tests and adjustments
are outlined in General Procedures.
• Always follow each step exactly and make
notes to recall important findings later.

Customer interview
The road test and customer interview (if
available) provide information that will help

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100-04-3 Noise, Vibration and Harshness 100-04-3

DIAGNOSIS AND TESTING (Continued)

• In certain conditions, the pitch of the exhaust Vibration Conditions

may sound very much like gear noise. At
Vibration at highway speeds may be caused by
other times, it can be mistaken for a wheel
the following:
bearing rumble.
• Tires, especially snow tires, can have a high • out-of-balance front or rear wheels
pitched tread whine or roar, similar to gear • out-of-round tires
noise. Radial tires may have this Shudder or vibration during acceleration may be
characteristic. Also, any non-standard tire caused by the following:
with an unusual tread construction may emit a
roar or whine noise. • damaged powertrain/drivetrain mounts
• Trim panels can also cause whistling or • excessively high constant velocity (CV) joint
whining noise. operating angles caused by incorrect ride
• Clunk may be a metallic noise heard when height. Check ride height, verify correct spring
the automatic transaxle is engaged in reverse rate and check items under inoperative
or drive, or it may occur when the throttle is conditions.
applied or released. It is caused by backlash
somewhere in the driveline.
Road Test
• Bearing rumble sounds like marbles being
tumbled. This condition is usually caused by a A gear-driven unit will produce a certain amount
damaged wheel bearing. of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving
conditions, as on a newly paved asphalt road.
Noise Conditions The slight noise is in no way detrimental and
• Gear noise is typically a howling or whining must be considered normal.
due to gear damage or incorrect bearing The road test and customer interview (if
preload. It can occur at various speeds and available) provide information needed to identify
driving conditions, or it can be continuous. the condition and give direction to the correct
• Chuckle is a particular rattling noise that starting point for diagnosis.
sounds like a stick against the spokes of a
spinning bicycle wheel. It occurs while
decelerating from 64 km/h (40 mph) and can
usually be heard all the way to a stop. The
frequency varies with vehicle speed.
• Knock is very similar to chuckle, though it
may be louder and occurs on acceleration or
deceleration. The teardown will disclose what
has to be corrected
Clicking, popping or grinding noises may be
caused by the following:
• worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to
diagnose and correct gear noise.
The noises described under Road Test usually
have specific causes that can be diagnosed by
observation as the unit is disassembled. The
initial clues are the type of noise heard on the
road test and driving conditions.

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100-04-4 Noise, Vibration and Harshness 100-04-4

DIAGNOSIS AND TESTING (Continued)

1. Make notes throughout the diagnosis routine. Boom/Shake/Vibration in the Symptom
Make sure to write down even the smallest Chart.
bit of information, because it may turn out to 3. High Speed: A vibration is felt in the front
be the most important. floor pan or seats with no visible shake, but
2. Do not touch anything until a road test and a with an accompanying sound or rumble,
thorough visual inspection of the vehicle buzz, hum, drone or booming noise. Coast
have been carried out. Leave the tire with the clutch pedal depressed (manual
pressures and vehicle load just where they transmission) or shift control selector lever in
were when the condition was first observed. neutral (automatic transmission) and engine
Adjusting tire pressures, vehicle load or idling. If vibration is still evident, it may be
making other adjustments may reduce the related to wheels, tires, front brake discs,
condition(s) intensity to a point where it wheel hubs or front wheel bearings. Refer to
cannot be identified clearly. It may also inject Shake and Vibration While Driving in the
something new into the system, preventing Symptom Chart.
correct diagnosis. 4. Engine rpm Sensitive: A vibration is felt
3. Make a visual inspection as part of the whenever the engine reaches a particular
preliminary diagnosis routine, writing down rpm. It will disappear in neutral coasts. The
anything that does not look right. NOTE tire vibration can be duplicated by operating the
pressures, but do not adjust them yet. NOTE engine at the problem rpm while the vehicle
leaking fluids, loose nuts and bolts, or bright is stationary. It can be caused by any
spots where components may be rubbing component, from the accessory drive belt to
against each other. Check the load space for the clutch or torque converter which turns at
unusual loads. engine speed when the vehicle is stopped.
4. Road test the vehicle and define the Refer to Shake and Vibration While Driving in
condition by reproducing it several times the Symptom Chart.
during the road test. 5. Noise and Vibration While Turning: Clicking,
5. Carry out the Road Test Quick Checks as popping, or grinding noises may be due to
soon as the condition is reproduced. This will the following:
identify the correct diagnostic procedure. • worn, damaged or incorrectly installed front
Carry out the Road Test Quick Checks more wheel bearing
than once to verify they are providing a valid • damaged powertrain/drivetrain mounts
result. Remember, the Road Test Quick
Checks may not tell where the concern is,
but they will tell where it is not. Road Conditions
An experienced technician will always establish a
Road Test Quick Checks route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
1. 24-80 km/h (15-50 mph): with light smooth, level and free of undulations (unless a
acceleration, a moaning noise is heard and particular condition needs to be identified). A
possibly a vibration felt in the front floor pan. smooth asphalt road that allows driving over a
It is usually worse at a particular engine range of speeds is best. Gravel or bumpy roads
speed and at a particular throttle setting are unsuitable because of the additional road
during acceleration at that speed. It may also noise produced. Once the route is established
produce a moaning sound, depending on and consistently used, the road noise variable is
what component is causing it. Refer to Tip-in eliminated from the test results.
Moan in the Symptom Chart.
NOTE: Some concerns may be apparent only on
2. Acceleration/Deceleration: With slow
smooth asphalt roads.
acceleration and deceleration, a shake is
sometimes noticed in the steering If a customer complains of a noise or vibration on
wheel/column, seats, front floor pan, front a particular road and only on a particular road,
door trim panel or front end sheet metal. It is the source of the concern may be the road
a low frequency vibration (around 9-15 cycles surface. If possible, try to test the vehicle on the
per second). It may or may not be increased same type of road.
by applying the brakes lightly. Refer to Idle

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100-04-5 Noise, Vibration and Harshness 100-04-5

DIAGNOSIS AND TESTING (Continued)

Vehicle Preparation unless the vehicle is inoperative or the condition

could pose a hazard to the technician. After
Carry out a thorough visual inspection of the
verifying that the condition has been corrected,
vehicle before carrying out the road test. NOTE
make sure all components removed have been
anything which is unusual. Do not repair or adjust
installed.
any condition until the road test is carried out,
Symptom Chart

Condition Possible Sources Action

• Shake and vibration while driv- • Wheel end vibration. • GO to Pinpoint Test A
ing • Engine/transmission.
• Tip-in moan • Air cleaner. • GO to Pinpoint Test B
• Power steering (PAS).
• Powertrain.
• Powertrain/drivetrain mounts.
• Exhaust system.
• Idle • Cable(s)/hose(s). • GO to Pinpoint Test C
boom/shake/vibration/shudder • Powertrain/drivetrain mounts.
• Exhaust system.
• Wheel end vibration analysis • Suspension. • GO to Pinpoint Test D
• Wheel bearings.
• Non-axle noise • Trim Panels. • GO to Pinpoint Test E
• Air conditioning (A/C) system.
• Accessories.
After verifying that the condition has been cor-
rected, make sure all components removed have
Pinpoint Tests been installed.
NOTE: These Pinpoint Tests are designed to
take the technician through a step-by-step
diagnosis procedure to determine the cause of a
condition. It may not always be necessary to
follow the chart to its conclusion. Carry out only
the pinpoint test steps necessary to correct the
condition. Then check the operation of the
system to make sure the condition has been
corrected.
PINPOINT TEST A: SHAKE AND VIBRATION WHILE DRIVING
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral
coast test?
→ Yes
GO to A2
→ No
GO to Pinpoint Test D
A2: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Check the powertrain/drivetrain mounts.
• Are the mounts OK?

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100-04-6 Noise, Vibration and Harshness 100-04-6

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
Vehicle condition corrected. ROAD TEST as
necessary.
→ No
INSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST B: TIP-IN MOAN
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE AIR CLEANER
1 Check the air cleaner.
- Inspect the air cleaner, intake pipe, outlet
pipe, resonators and all other components
associated with the intake air filtering and dis-
tribution system for correct installation and
tightness of all connections.
• Are the components OK?
→ Yes
GO to B2
→ No
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
B2: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing pro-
cedure in this section.
• Is the exhaust system OK?
→ Yes
GO to B3
→ No
REPAIR as necessary. ROAD TEST as
necessary.
B3: CHECK THE POWER STEERING
1 Remove the accessory drive belt and test for
tip-in moan. REFER to Section 303-05.
• Is the tip-in moan OK?
→ Yes
REPAIR the power steering as necessary.
REFER to Section 211-02.
→ No
GO to B4
B4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Check the powertrain/drivetrain mounts
• Are the mounts OK?
→ Yes
Vehicle condition corrected. ROAD TEST as
necessary.
→ No
INSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.

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100-04-7 Noise, Vibration and Harshness 100-04-7

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: IDLE BOOM/SHAKE/VIBRATION/SHUDDER

CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE CABLE/HOSES
1 Check the engine compartment for any com-
ponent that may have a touch condition be-
tween the engine and body or chassis. For ex-
ample: control cable, air conditioning (A/C)
hoses, acceleration cable.
• Are the components OK?
→ Yes
GO to C2
→ No
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
C2: CHECK THE ENGINE COOLING RADIATOR
1 Check the engine cooling radiator mountings
and bushings for security and condition. Check
the radiator installation for any component that
may have a touch condition.
• Is the installation and bushings OK?
→ Yes
GO to C3
→ No
REPAIR or INSTALL new components as
necessary. ROAD TEST as necessary.
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing pro-
cedure in this section.
• Is the exhaust system OK?
→ Yes
GO to C4
→ No
REPAIR as necessary. ROAD TEST as
necessary.
C4: CHECK THE POWERTRAIN/DRIVETRAIN MOUNTS
1 Check the powertrain/drivetrain mounts.
• Are the mounts OK?
→ Yes
Vehicle condition corrected. ROAD TEST as
necessary.
→ No
INSTALL new powertrain/drivetrain mounts
as necessary. ROAD TEST as necessary.
PINPOINT TEST D: WHEEL END VIBRATION ANALYSIS
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: INSPECT THE WHEELS AND TIRES
1 Inspect the wheels and tires. REFER to Sec-
tion 204-04.

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100-04-8 Noise, Vibration and Harshness 100-04-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the wheels and tires OK?

→ Yes
GO to D2
→ No
INSTALL new wheels and tires as neces-
sary. REFER to Section 204-04. ROAD
TEST as necessary.
D2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings. REFER to Section
204-00.
• Are the wheel bearings OK?
→ Yes
GO to D3
→ No
INSTALL new wheel bearings as necessary.
ROAD TEST as necessary.
D3: INSPECT THE WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout. REFER to
Section 204-00.
• Is the wheel and tire runout OK?
→ Yes
Balance the wheels and tires. Refer to the
wheel balance equipment manufacturer's
instructions. ROAD TEST as necessary.
→ No
INSTALL new wheels and tires as neces-
sary. REFER to Section 204-04. ROAD
TEST as necessary.
PINPOINT TEST E: NON-AXLE NOISE
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: INSPECT THE VEHICLE TRIM
1 Inspect the grille and trim panels to see if they
are the source of the noise.
• Are the vehicle trim components causing the
noise?
→ Yes
INSTALL new trim components or REPAIR
as necessary.
→ No
GO to E2
E2: CHECK THE AIR CONDITIONING (A/C) SYSTEM FOR NOISE
1 Key in START position.
2 Key in ON position.
3 Check the A/C system components for noise
by turning the A/C system on and off.
• Is the A/C system causing the noise?
→ Yes

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100-04-9 Noise, Vibration and Harshness 100-04-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSPECT the A/C system. REFER to Sec-
tion 412-00.
→ No
GO to E3
E3: CHECK NON-FACTORY FITTED ACCESSORIES
1 Check any non-factory fitted accessories for
being the source of the noise. For example:
touch condition body-to-frame, antennas, sun
visors, deflectors and fog lights.
• Are the accessories the cause of the noise?
→ Yes
ADJUST, REPAIR, or INSTALL new acces-
sories or fasteners as required.
→ No
Vehicle is OK. VERIFY the customer con-
cern.

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100-04-10 Noise, Vibration and Harshness 100-04-10

GENERAL PROCEDURES

Exhaust System Neutralizing (25 001 0)

GENERAL PROCEDURES

1. Loosen the muffler inlet pipe and

resonator pipe to exhaust manifold
fasteners at the flanges and the muffler
inlet connection.
2. Place a stand to support the muffler
parallel to the vehicle frame with the
muffler pipe bracket free of stress.
3. Tighten the muffler connection.
4. Position the exhaust pipes to the
manifolds and tighten. Make sure that the
catalytic converter and heat shield do not
contact the frame rails.
5. With the complete exhaust system tight
(and cooled) the rear hanger insulator
should be angled forward, to allow the
system to expand rearward when heated
during normal running.

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 Group

SECTION TITLE PAGE

Suspension
Suspension System - General Information ............................................................................ 204-00-1
Front Suspension .................................................................................................................. 204-01-1
Rear Suspension................................................................................................................... 204-02-1
Wheels and Tires .................................................................................................................. 204-04-1
Driveline
Front Drive Halfshafts............................................................................................................ 205-04-1
Brake System
Brake System - General Information...................................................................................... 206-00-1
Front Disc Brake.................................................................................................................... 206-03-1
Rear Disc Brake .................................................................................................................... 206-04-1
Parking Brake and Actuation ................................................................................................. 206-05-1
Hydraulic Brake Actuation ..................................................................................................... 206-06-1
Power Brake Actuation .......................................................................................................... 206-07-1
Anti-Lock Control................................................................................................................... 206-09A-1
Anti-Lock Control - Stability Assist ......................................................................................... 206-09B-1
Steering System
Steering System - General Information.................................................................................. 211-00-1
Power Steering...................................................................................................................... 211-02-1
Steering Linkage ................................................................................................................... 211-03-1
Steering Column.................................................................................................................... 211-04-1

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204-00-1 Suspension System - General Information 204-00-1

SECTION 204-00 Suspension System - General

Information
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 204-00-2

Front Wheel Alignment (at kerb weight) — Caster (Vehicles with 1.8L, 2.0L or 2.5L en-
gines) ............................................................................................................................ 204-00-2
Front Wheel Alignment (at kerb weight) — Caster (Vehicles with 3.0L engines)............... 204-00-2
Front Wheel Alignment (at kerb weight) — Camber (Vehicles with 1.8L, 2.0L or 2.5L en-
gines) ............................................................................................................................ 204-00-2
Front Wheel Alignment (at kerb weight) — Camber (Vehicles with 3.0L engines)............. 204-00-2
Front Wheel Alignment (at kerb weight) — Total Toe Setting ........................................... 204-00-2
Rear Wheel Alignment (at kerb weight) — Camber (Vehicles with 1.8L, 2.0L or 2.5L en-
gines) ............................................................................................................................ 204-00-2
Rear Wheel Alignment (at kerb weight) — Camber (Vehicles with 3.0L engines) ............. 204-00-3
Rear Wheel Alignment (at kerb weight) — Total Toe Setting ............................................ 204-00-3

DIAGNOSIS AND TESTING

Suspension System........................................................................................................... 204-00-4

Inspection and Verification ............................................................................................... 204-00-4
Symptom Chart ................................................................................................................ 204-00-4
Pinpoint Tests .................................................................................................................. 204-00-6
Component Tests ............................................................................................................. 204-00-12

GENERAL PROCEDURES

Wheel Bearing Inspection.................................................................................................. 204-00-13

Front Toe Adjustment ................................................................................... (14 117 0) 204-00-14
Rear Toe Adjustment.................................................................................... (15 211 0) 204-00-15

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204-00-2 Suspension System - General Information 204-00-2

SPECIFICATIONS

Front Wheel Alignment (at kerb weight) — Caster (Vehicles with 1.8L, 2.0L or 2.5L engines)
Model Decimal Degrees Degrees and Minutes
Nominal Tolerance Range Nominal Tolerance Range
4-door and 5-door +2.65° +3.77° to +1.53° +2° 39' +3° 46' to +1° 31'
Wagon without load levelling +2.30° +3.40° to +1.20° +2° 18' +3° 24' to +1° 12'
shock absorber
Wagon with load levelling shock +2.08° +3.16° to +1.00° +2° 05' +3° 10' to +1° 00'
absorber
Maximum variance left-hand side to right-hand side Caster 1.00° (1° 00')

Front Wheel Alignment (at kerb weight) — Caster (Vehicles with 3.0L engines)
Model Decimal Degrees Degrees and Minutes
Nominal Tolerance Range Nominal Tolerance Range
4-door and 5-door +2.54° +3.56° to +1.52° +2° 32' +3° 34' to +1° 31'
Wagon without load levelling +2.30° +3.40° to +1.20° +2° 18' +3° 24' to +1° 12'
shock absorber
Wagon with load levelling shock +2.31° +3.31° to +1.31° +2° 19' +3° 19' to +1° 19'
absorber
Maximum variance left-hand side to right-hand side Caster 1.00° (1° 00')

Front Wheel Alignment (at kerb weight) — Camber (Vehicles with 1.8L, 2.0L or 2.5L engines)
Model Decimal Degrees Degrees and Minutes
Nominal Tolerance Range Nominal Tolerance Range
4-door and 5-door -0.55° +0.75° to -1.85° -0° 33' +0° 45' to -1° 51'
Wagon without load levelling -0.60° +0.72° to -1.87° -0° 36' +0° 43' to -1° 52'
shock absorber
Wagon with load levelling shock -0.60° +0.67° to -1.87° -0° 36' +0° 40' to -1° 52'
absorber
Maximum variance left-hand side to right-hand side Camber 1.25° (1° 15')

Front Wheel Alignment (at kerb weight) — Camber (Vehicles with 3.0L engines)
Model Decimal Degrees Degrees and Minutes
Nominal Tolerance Range Nominal Tolerance Range
All vehicles -1.00° +0.25° to -2.25° -1° 00' -0° 15' to -2° 15'
Maximum variance left-hand side to right-hand side Camber 1.25° (1° 15')

Front Wheel Alignment (at kerb weight) — Total Toe Setting

Derivative Tolerance Range Setting Adjustment, if required
All variants (decimal degrees) -0.00° (Toe-out) ± 0.35° -0.00° (Toe-out) ± 0.14°
All variants (degrees and minutes) -0° 00' (Toe-out) ± 0° 21' -0° 00' (Toe-out) ± 0° 08'
All variants (mm) -0.0 mm (Toe-out) ± 2.5 mm -0.0 mm (Toe-out) ± 1.0 mm

Rear Wheel Alignment (at kerb weight) — Camber (Vehicles with 1.8L, 2.0L or 2.5L engines)
Model Decimal Degrees Degrees and Minutes
Nominal Tolerance Range Nominal Tolerance Range
4-door and 5-door -1.21° +0.14° to -2.56° -1° 12' +0° 08' to -2° 33'

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204-00-3 Suspension System - General Information 204-00-3

SPECIFICATIONS (Continued)

Model Decimal Degrees Degrees and Minutes

Nominal Tolerance Range Nominal Tolerance Range
Wagon without load levelling -0.92° +0.38° to -2.22° -0° 55' +0° 22' to -2° 13'
shock absorber
Wagon with load levelling shock -0.77° +0.53° to -2.07° -0° 46' +0° 31' to -2° 04'
absorber
Maximum variance left-hand side to right-hand side Camber 1.25° (1° 15')

Rear Wheel Alignment (at kerb weight) — Camber (Vehicles with 3.0L engines)
Model Decimal Degrees Degrees and Minutes
Nominal Tolerance Range Nominal Tolerance Range
4-door and 5-door -1.33° -0.06° to -2.60° -1° 20' -0° 04' to -2° 36'
Wagon without load levelling -0.92° +0.38° to -2.22° -0° 55' -0° 22' to -2° 13'
shock absorber
Wagon with load levelling shock -1.27° -0.02° to -2.52° -1° 16' +0° 01' to -2° 31'
absorber
Maximum variance left-hand side to right-hand side Camber 1.25° (1° 15')

Rear Wheel Alignment (at kerb weight) — Total Toe Setting

Derivative Tolerance Range Setting Adjustment, if required
All variants (decimal degrees) 0.45° (Toe-in) ± 0.34° 0.28° (Toe-in) ± 0.14°
All variants (degrees and minutes) 0° 27' (Toe-in) ± 0° 20' 0° 17' (Toe-in) ± 0° 08'
All variants (mm) 3.2 mm (Toe-in) ± 2.5 mm 2.0 mm (Toe-in) ± 1.0 mm

Torque Specifications
Description Nm lb-ft lb-in
Tie-rod end locknut 40 30 –

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204-00-4 Suspension System - General Information 204-00-4

DIAGNOSIS AND TESTING

Suspension System
DIAGNOSIS AND TESTING

3. If an obvious cause for an observed or

reported concern is found, correct the cause
Inspection and Verification (if possible) before proceeding to the next
1. Verify the customer concern. step.
2. Visually inspect for obvious signs of 4. If the concern is not visually evident, verify
mechanical damage. the symptom and refer to the Symptom
Chart.
Visual Inspection Chart
Mechanical
- Tire pressure
- Wheel and tires
- Wheel knuckles
- T ie-rod ends
- Front suspension lower arm ball joints
- Front suspension lower arm bushings
- Front strut and spring assemblies
- Front and rear stabilizer bar and connecting
links
- Rear springs
- Rear shock absorbers
- Rear suspension lower arms
Symptom Chart

Condition Possible Sources Action

• Drift left or right • Vehicle attitude incorrect (front • CHECK for abnormal loading,
or rear is high or low). coil spring sag, or non-standard
springs.
• Steering gear or linkage worn or • CHECK the steering system.
damaged. REFER to Section 211-00.
• Brake system. • CHECK the brakes. REFER to
Section 206-00.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Worn front wheel bearings. • CHECK the front wheel bear-
ings. REFER to Wheel Bearing
Inspection in this Section.
• Wheel and tires. • Go to Pinpoint Test A.
• Steering wheel off center • Vehicle attitude incorrect (front • CHECK for abnormal loading,
or rear is high or low). coil spring sag or non-standard
springs.
• Steering gear or linkage. • CHECK the steering system.
REFER to Section 211-00.
• Suspension lower arm ball joint. • CARRY OUT the Ball Joint
Component Test in this section.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Tracks incorrectly • Incorrect castor angle. • GO to Pinpoint Test B.

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204-00-5 Suspension System - General Information 204-00-5

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Rear suspension damage. • GO to Pinpoint Test B.
• Rough ride • Front or rear stabilizer connect- • CHECK or INSTALL new sus-
ing bar, links or bushings. pension components as neces-
sary. REFER to Section 204-01
/ 204-02.
• Front suspension lower arm • CHECK or INSTALL new sus-
bushing. pension components as neces-
sary. REFER to Section 204-01.
• Rear suspension arm bushing. • CHECK or INSTALL new com-
ponents as necessary. REFER
to Section 204-02.
• Front strut and spring assem- • GO to Pinpoint Test C.
blies.
• Rear shock absorbers. • GO to Pinpoint Test C.
• Excessive noise • Worn front wheel bearings. • CHECK the wheel bearings.
REFER to Wheel Bearing In-
spection in this Section.
• Suspension lower arm ball joint. • CARRY OUT the Ball Joint
Component test in this Section
• Suspension damage. • GO to Pinpoint Test D
• Incorrect tire wear • Incorrect tire pressure. • ADJUST the tire pressure.
REFER to the Owner's Guide.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Vibration • Damaged or worn front wheel • CHECK the front wheel bear-
bearings. ings. REFER to Wheel Bearing
Inspection in this Section.
• Wheels and tires. • CHECK the tires. BALANCE or
INSTALL new tires as neces-
sary. REFER to Section 204-04.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Steering system inoperative. • CHECK the steering system.
REFER to Section 211-00.
• Front strut and spring assem- • GO to Pinpoint Test C.
blies.
• Damaged front suspension • GO to Pinpoint Test D.
lower arm(s).
• Wheel and tire excessive • GO to Pinpoint Test E.
runout.

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204-00-6 Suspension System - General Information 204-00-6

DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests
PINPOINT TEST A: DRIFT LEFT OR RIGHT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: To avoid personal injury due to the loss of vehicle control, the inspection
should be carried out by two people to maintain safe driving conditions. Adequate grip
should always be maintained on the steering wheel. Failure to follow these instructions
may result in personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to
Section 100-02.
- Swap the front left-hand wheel and tire
assembly with the front right-hand wheel and
tire assembly.
- Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A2
→ No
The concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to
Section 100-02.
- Swap the rear left-hand wheel and tire
assembly with the rear right-hand wheel and
tire assembly.
- Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A3
→ No
The concern has been corrected.
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to
Section 100-02.
- Swap the front left-hand wheel and tire
assembly with the rear left-hand wheel and
tire assembly.
- Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A4
→ No
The concern has been corrected.

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204-00-7 Suspension System - General Information 204-00-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to
Section 100-02.
- Swap the front right-hand wheel and tire
assembly with the rear right-hand wheel and
tire assembly.
- Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A5
→ No
The concern has been corrected.
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle.
- Swap the front left-hand wheel and tire
assembly with the rear right-hand wheel and
tire assembly.
- Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A6
→ No
The concern has been corrected.
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle. REFER to
Section 100-02.
- Swap the front right-hand wheel and tire
assembly with the rear left-hand wheel and
tire assembly.
- Road test the vehicle.
• Does the vehicle drift?
→ Yes
GO to A7
→ No
The concern has been corrected.
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1 Install new tires to the four road wheels. TEST
the system for normal operation.
• Does the vehicle drift?
→ Yes
Verify possible sources, refer to the Symp-
tom Chart.
→ No
The concern has been corrected.

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204-00-8 Suspension System - General Information 204-00-8

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: TRACKS INCORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE CASTOR
1 Check the vehicle wheel alignment.
• Is the castor angle within specification?
→ Yes
GO to B2
→ No
INSTALL new suspension components as
necessary. ADJUST alignment to specifica-
tion. TEST the system for normal operation.
B2: CHECK THE REAR SUSPENSION
1 Measure the vehicle wheel base left-hand and
right-hand side.
- Compare the measurements.
• Are the measurements the same?
→ Yes
VERIFY the customer concern.
→ No
INSPECT the rear suspension components
for wear or damage. INSTALL new compo-
nents as necessary. REFER to Section 204-
02. TEST the system for normal operation.
PINPOINT TEST C: ROUGH RIDE
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE FRONT STRUT AND SPRING ASSEMBLIES
1 Raise and support the vehicle. REFER to
Section 100-02.
- Inspect the front strut and spring assemblies
for oil leaks or damage.
• Are the front strut and spring assemblies dam-
aged or leaking?
→ Yes
INSTALL new components as necessary.
REFER to Section 204-01. TEST the sys-
tem for normal operation.
→ No
GO to C2
C2: CHECK THE REAR SHOCK ABSORBERS
1 Raise and support the vehicle. REFER to
Section 100-02.
- Inspect the rear shock absorbers for oil leaks
or damage.
• Are the rear shock absorbers damaged or leak-
ing?
→ Yes
INSTALL new components as necessary.
REFER to Section 204-02. TEST the sys-
tem for normal operation.
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204-00-9 Suspension System - General Information 204-00-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
VERIFY the customer concern.
PINPOINT TEST D: EXCESSIVE NOISE
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: INSPECT THE SUSPENSION
1 Raise and support the vehicle. REFER to
Section 100-02.
- Inspect the suspension mounting bolts.
• Are the mounting bolts loose or broken?
→ Yes
TIGHTEN or INSTALL new suspension
mounting bolts. REFER to Section 204-01.
(Front). REFER to Section 204-02. (Rear).
TEST the system for normal operation.
→ No
GO to D2
D2: INSPECT THE SPRINGS
1 Inspect the springs for damage.
• Are the springs damaged?
→ Yes
INSTALL new springs. REFER to Section
204-01. (Front). REFER to Section 204-02.
(Rear). TEST the system for normal opera-
tion.
→ No
GO to D3
D3: INSPECT THE FRONT SUSPENSION LOWER ARM
1 Inspect the front suspension lower arm bush-
ings for excessive wear or damage.
• Are the front suspension lower arm bushings
worn or damaged?
→ Yes
INSTALL new lower arm. REFER to Section
204-01. TEST the system for normal opera-
tion.
→ No
GO to D4
D4: INSPECT THE TIRES
1 Inspect the tires for uneven wear.
• Is there uneven wear?
→ Yes
INSTALL new tires. ADJUST the wheel
alignment to specification. TEST the system
for normal operation.
→ No
VERIFY the customer concern.

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204-00-10 Suspension System - General Information 204-00-10

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E: VIBRATION
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: INSPECT THE TIRES
1 Raise and support the vehicle. REFER to
Section 100-02.
- Inspect the tires for damage or excessive
wear.
• Are the tires damaged or worn?
→ Yes
INSTALL new tires. TEST the system for
normal operation.
→ No
GO to E2
E2: MEASURE THE WHEEL AND TIRE RUNOUT ON THE VEHICLE
1 Measure the wheel and tire runouts on the ve-
hicle using suitable equipment. Assembly
runout should be less than 1.14 mm (0.045
inch) radial and lateral.
• Is the measurement within specification?
→ Yes
GO to E8
→ No
GO to E3
E3: MEASURE THE WHEEL AND TIRE RUNOUT OFF THE VEHICLE
1 Measure the wheel and tire from any position
that exceeds 1.14 mm (0.045 inch) radial or
lateral. Before removing the wheel, mark a
wheel stud and corresponding stud hole so the
wheel can be installed in same position. Re-
move the wheel and mount on a wheel balan-
cer. Measure the runout. Wheel and tire runout
should be less than 1.14 mm (0.045 inch) ra-
dial and lateral.
• Is the measurement to specification?
→ Yes
GO to E6
→ No
GO to E4
E4: MATCH MOUNTING
1 Mark the high runout location on the tire and
also on the wheel. Deflate the tire and rotate
the tire 180 degrees on the wheel. Inflate the
tire and measure the runouts.
• Are the wheel and tire balanced?
→ Yes
INSTALL the wheel to the vehicle. TEST the
system for normal operation.
→ No

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204-00-11 Suspension System - General Information 204-00-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
If the high spot is not within 101.6 mm (4
inches) of first high spot on the tire,
GO to E5
E5: MEASURE WHEEL RUNOUT
1 Remove the tire and mount the wheel on a
wheel balancer. Measure the runout on both
flanges. Runout should be less than 1.14 mm
(0.045 inch) radial and lateral.
• Is the runout to specification?
→ Yes
LOCATE and MARK the low spot on wheel
and INSTALL the tire matching the high spot
on the wheel. BALANCE the wheel and tire
assembly. TEST the system for normal op-
eration.
→ No
INSTALL a new wheel. CHECK the runout
on the new wheel. If the new wheel is within
limits, LOCATE and MARK the low spot.
INSTALL the tire, matching the high spot of
the tire with the low spot of the wheel.
BALANCE the wheel and tire assembly.
INSTALL the wheel and tire to the vehicle.
TEST the system for normal operation.
E6: REAR HUB AND STUD PITCH CIRCLE DIAMETER RUNOUT
1 Remove the rear wheel and brake drum or
disc.
- Measure the hub flange face runout (greater
than 0.254 mm (0.010 inch)), stud circle
runout (greater than 0.08 mm (0.003 inch))
and radial runout (greater than 0.05 mm
(0.002 inch)).
• Are the measurements correct?
→ Yes
GO to E7
→ No
INSTALL a new rear hub. REFER to Section
204-02.
E7: FRONT HUB AND STUD PITCH CIRCLE DIAMETER RUNOUT
1 Remove the front wheel and brake disc.
- Measure the stud circle runout (greater than
0.06 mm (0.002 inch)).
• Are the measurements correct?
→ Yes
GO to E8
→ No
INSTALL a new hub. REFER to Section
204-01.
E8: WHEEL BALANCE
1 Balance all wheels. Road test the vehicle.

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204-00-12 Suspension System - General Information 204-00-12

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is a vibration felt?
→ Yes
REFER to Section 100-04.
→ No
VERIFY the customer concern.

Component Tests
Ball Joint Inspection
1. Raise and support the vehicle. REFER to
Section 100-02.
2. Firmly grasp the outer end of the suspension
lower arm and try to move it up and down,
watching and feeling for any movement. Free
movement will usually be accompanied by an
audible "click''. There should be no free
movement.
3. If there is any free movement install a new
lower arm. REFER to Section 204-01.
4. If a new lower arm is installed it will be
necessary to check and adjust the front
wheel alignment. For additional information,
refer to Specifications in this Section.

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204-00-13 Suspension System - General Information 204-00-13

GENERAL PROCEDURES

Wheel Bearing Inspection

GENERAL PROCEDURES

5. Position a suitable Dial indicator gauge

fixture or equivalent, against the wheel
hub, then push and pull the wheel hub.
Special Tool(s) Measure the end play of the wheel hub and
Holding Fixture, Dial Indicator front wheel bearing assembly. There
Gauge should be no end play. If end play exists,
install new wheel bearings.
205-044 (15-008)

General Equipment
Dial indicator gauge

Check
1. NOTE: Do not to confuse lower arm ball joint
looseness with bearing looseness.
Raise and support the front of the vehicle.
For additional information, refer to Section
100-02. 6. Install the front brake caliper. For
additional information, refer to Section
2. Check for loose front wheel bearings by 206-03.
rocking the wheels at the top and bottom.

3. Spin the wheel quickly by hand and make

sure the wheel turns smoothly without
noise from the wheel bearings.
4. Remove the front brake caliper and anchor
plate. For additional information, refer to
Section 206-03.

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204-00-14 Suspension System - General Information 204-00-14

GENERAL PROCEDURES

Front Toe Adjustment (14 117 0)

NOTE: The checking and subsequent adjustment

of the front toe setting should be carried out on a
4. Rotate the tie-rods an equal amount in ei-
flat surface and in accordance with the
ther a clockwise or a counterclockwise di-
manufacturers instructions for the wheel
rection to adjust the toe setting.
alignment equipment used.
1. Centralize the steering and lock it in posi-
tion.

5. Tighten the tie-rod end locknuts. For addi-

tional information, refer to Section 211-03.
2. Loosen the tie-rod end locknuts.

6. Install the steering gear boot outer clamps.

3. Remove the steering gear boot outer
clamps.

7. Check the toe setting.

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204-00-15 Suspension System - General Information 204-00-15

GENERAL PROCEDURES

Rear Toe Adjustment (15 211 0)

5. Lower the vehicle.

General Equipment • Bounce the vehicle to make sure that the
suspension is in its normal resting position.
Four wheel alignment equipment
6. Adjust the toe setting (Wagon shown, 4-
NOTE: The checking and subsequent adjustment door and 5-door similar).
of the rear toe setting should be carried out on a
flat surface and in accordance with the
manufacturers instructions for the particular
wheel alignment equipment being used.
1. NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.
Using suitable four wheel alignment
equipment, check the toe setting.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
3. Loosen the rear lower arm cam nut
(Wagon shown, 4-door and 5-door similar).
7. Tighten the lower arm cam nut (Wagon
shown, 4-door and 5-door similar)

4. NOTE: Do not fully tighten the lower arm cam

nut at this stage (Wagon shown, 4-door and 5-
door similar).
Tighten the lower arm cam nut.

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204-01-1 Front Suspension 204-01-1

SECTION 204-01 Front Suspension

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 204-01-2

DESCRIPTION AND OPERATION

Front Suspension .............................................................................................................. 204-01-3

DIAGNOSIS AND TESTING

Front Suspension .............................................................................................................. 204-01-5

REMOVAL AND INSTALLATION

Wheel Bearing.............................................................................................. (14 411 0) 204-01-6

Lower Arm .................................................................................................... (14 706 0) 204-01-8
Stabilizer Bar ................................................................................................ (14 752 0) 204-01-14
Stabilizer Bar Bushing .................................................................................. (14 754 0) 204-01-22
Wheel Knuckle ............................................................................................. (14 343 0) 204-01-23
Strut and Spring Assembly ........................................................................... (14 781 0) 204-01-33

DISASSEMBLY AND ASSEMBLY

Strut and Spring Assembly ........................................................................... (14 783 4) 204-01-41

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204-01-2 Front Suspension 204-01-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Stabilizer bar connecting link nuts 48 35 –
Stabilizer bar clamp retaining bolts 48 35 –
Subframe retaining bolts 142 105 –
Lower arm to subframe rear retaining nut and bolt a) – –
Lower arm to subframe front retaining bolt a) – –
Wheel knuckle pinch bolt 83 61 –
Lower arm to wheel knuckle pinch nut and bolt 83 61 –
Wheel hub retaining nut 290 214 –
Top mount retaining nuts 30 22 –
Thrust bearing retaining nut 59 44 –
Wheel speed sensor retaining bolt 6 – 53
Brake caliper anchor plate retaining bolt 130 96 –
Engine rear support insulator retaining bolt 80 59 –
Steering gear retaining bolts 130 96 –
Tie-rod end retaining nut 40 30 –
Radiator support bracket retaining bolts 25 18 –
Steering column shaft to flexible coupling bolt 20 15 –
Brake hose support bracket retaining nut 48 35 –
a) Refer to the procedure in this section.

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204-01-3 Front Suspension 204-01-3

DESCRIPTION AND OPERATION

Front Suspension
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
4 Strut
1 Stabilizer bar
5 Wheel speed sensor
2 Stabilizer bar connecting link
6 Wheel knuckle
3 Spring
7 Wheel hub

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204-01-4 Front Suspension 204-01-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
8 Lower arm ball joint heat
shield
9 Lower arm
10 Subframe

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204-01-5 Front Suspension 204-01-5

DIAGNOSIS AND TESTING

Front Suspension
DIAGNOSIS AND TESTING

REFER to Section 204-00.

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204-01-6 Front Suspension 204-01-6

REMOVAL AND INSTALLATION

Wheel Bearing (14 411 0)

REMOVAL AND INSTALLATION

Removal
Special Tool(s)
1. Remove the wheel knuckle. For additional
Adapter for 204-158 (Thrust information, refer to Wheel Knuckle in this
Pad) section.
204-158-01 (14-038-01) 2. Remove the front wheel speed sensor.

Installer, Front Wheel

Bearing
204-160 (14-040)

Adapter for 205-066

205-066-03 (15-033-03)

Adapter for 205-066 3. NOTE: When removing the wheel hub from the
205-066-04 (15-068) wheel knuckle the bearing will be destroyed.
The bearing inner ring will be on the wheel
hub and the bearing outer ring will be in the
wheel knuckle.
Using a suitable bearing seperator and the
Adapter for 205-074 special tools, remove the wheel hub.
205-074-01 (15-064)

Installer, Rear Hub Oil Seal

205-075 (15-036)

Installer, Wheel Hub Bearing

Cone/Seal
205-101 (15-051)

General Equipment
Bearing separator

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204-01-7 Front Suspension 204-01-7

REMOVAL AND INSTALLATION (Continued)

4. CAUTION: A suitable bearing seperator 1. CAUTION: Make sure the mating

and the special tools must be used to surfaces of the wheel bearing and the
prevent damage to the hub. If the hub wheel knuckle are free from oil and
is damaged a new hub must be grease.
installed.
CAUTION: Make sure the wheel bearing
CAUTION: Do not use heat to remove the is installed into the wheel knuckle with
bearing inner ring. the wheel speed sensor ring, colored
black, at the wheel speed sensor end of
Using a suitable bearing seperator and the
the wheel knuckle.
special tools, remove the bearing inner
ring. Using the special tools, install the new
wheel bearing.

5. Using the special tool, remove the bearing

outer ring. 2. Using the special tools, install the wheel
hub.

Installation 3. Install the wheel knuckle. For additional

information, refer to Wheel Knuckle in this
CAUTION: Avoid any impact on the wheel section.
speed sensor ring.
CAUTION: Make sure the wheel speed
sensor ring is clean.
CAUTION: Avoid any contact between the
wheel speed sensor ring and a magnetic
surface.

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204-01-8 Front Suspension 204-01-8

REMOVAL AND INSTALLATION

Lower Arm (14 706 0)

All vehicles
4. Detach the splash shield from the sub-
frame.
Special Tool(s)
Alignment Pins, Subframe
205-316 (15-097A)

Angle Gauge, Bolt Tightening

303-174 (21-540)

General Equipment
5. NOTE: Only one side of the subframe needs to
Transmission jack be lowered for the removal of the lower arm.
Wooden block Using a suitable wooden block and a
transmission jack, support the side of the
subframe to be lowered.
Removal
All vehicles
1. Remove the wheel and tire. For
additional information, refer to Section
204-04.
Vehicles with diesel engine
2. Remove the engine undershield.

6. Remove the subframe rear retaining bolt

and the subframe rear bracket retaining
bolts, on the side the lower arm is being
removed (right-hand side shown).

Vehicles with xenon headlamps

3. NOTE: The left-hand lower arm is equipped
with a headlamp leveling sensor.
Remove the headlamp leveling sensor.
For additional information, refer to Section
417-01.

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204-01-9 Front Suspension 204-01-9

REMOVAL AND INSTALLATION (Continued)

7. Loosen the subframe rear retaining bolt 11. CAUTION: To prevent damage to the
and the subframe rear bracket retaining lower arm hydro-bushing, make sure
bolts, on the opposite side, by five turns. the subframe is lowered before
detaching the lower arm ball joint from
8. Remove the subframe front retaining bolt,
the wheel knuckle.
on the side the lower arm is being re-
moved (right-hand side shown). Remove the lower arm ball joint to wheel
knuckle pinch bolt and nut.

9. Loosen the subframe front retaining bolt,

on the opposite side, by five turns. 12. CAUTION: Protect the ball joint seal
10. Lower the subframe to gain access to the using a soft cloth to prevent damage.
lower arm rear retaining bolt.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

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204-01-10 Front Suspension 204-01-10

REMOVAL AND INSTALLATION (Continued)

13. Remove the lower arm. 2. CAUTION: Make sure the heat shield is
• Discard the retaining bolts and nut. installed to prevent damage to the ball
joint.
Install the heat shield.

Installation
3. CAUTION: The lower arm pinch bolt
All vehicles
must be installed from the rear of the
NOTE: Final tightening of the lower arm retaining wheel knuckle.
bolts should be carried out when the vehicle
weight is on the road wheels. Attach the lower arm ball joint to the wheel
knuckle.
1. WARNING: Install a new front retaining
bolt and rear retaining bolt and nut.
Failure to follow this instruction may
result in personal injury.
NOTE: Do not fully tighten the lower arm
retaining bolts at this stage.
Install the lower arm.

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204-01-11 Front Suspension 204-01-11

REMOVAL AND INSTALLATION (Continued)

4. Using the special tool and a suitable 6. Tighten the subframe rear retaining bolt
washer, align the subframe. and the subframe bracket retaining bolts,
1. Insert the washer, with inside diameter 22 on the opposite side (left-hand side
mm, outside diameter 44 mm and height 5 shown).
mm, into the subframe above the lower
alignment hole.
2. Insert the alignment pin through the
subframe alignment holes and the washer.
3. Slide the locking plates on top of the
washer and into the groove of the tool and
tighten the alignment pin sleeve.

7. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe front retaining bolt, on
the side the lower arm was installed (right-
hand side shown).

5. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolt and
the subframe bracket retaining bolts, on
the side the lower arm was installed (right-
hand side shown).

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204-01-12 Front Suspension 204-01-12

REMOVAL AND INSTALLATION (Continued)

8. Tighten the subframe front retaining bolt, Vehicles with xenon headlamps
on the opposite side (left-hand side 11. NOTE: The left-hand lower arm is equipped
shown). with a headlamp leveling sensor.
• Lower and remove the transmission jack.
Install the headlamp leveling sensor.
For additional information, refer to
Section 417-01.
All vehicles
12. Install the wheel and tire. For additional
information, refer to Section 204-04.
13. Tighten the lower arm front retaining bolt
in two stages.
• Stage 1: 80 Nm
• Stage 2: 60 degrees

9. Remove the special tools.

14. Tighten the lower arm rear retaining bolt

in two stages.
• Stage 1: 90 Nm
• Stage 2: 60 degrees

10. Attach the splash shield to the subframe.

Vehicles with diesel engine

15. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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204-01-13 Front Suspension 204-01-13

REMOVAL AND INSTALLATION (Continued)

16. Install the engine undershield.

17. Lower the vehicle.

All vehicles
18. Check the toe setting and adjust as
necessary. For additional information,
refer to Section 204-00.
Vehicles with xenon headlamps
19. Initialize the headlamp leveling system
using WDS.

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204-01-14 Front Suspension 204-01-14

REMOVAL AND INSTALLATION

Stabilizer Bar (14 752 0)

2. Detach the steering column shaft from the
steering column flexible coupling.
Special Tool(s) 1. Remove the retaining bolt.
2. Rotate the clamp plate.
Alignment Pins, Subframe
• Discard the bolt.
205-316 (15-097A)

General Equipment
Transmission jack

Name Specification
Anti-seize grease SAM-1C9107-A

Removal
3. Using suitable pins, support the radiator
All vehicles on the radiator grill opening panel (left-
hand side shown).
1. NOTE: Make sure the road wheels are in the
straight ahead position.
Centralize the steering and lock it in posi-
tion.

4. Remove the front wheels and tires. For

additional information, refer to Section
204-04.

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204-01-15 Front Suspension 204-01-15

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engines 8. Remove the coolant hose support bracket.
5. Remove the engine undershield.

9. NOTE: Use a 5 mm Allen key to prevent the

All vehicles ball joint from rotating.
6. Remove the splash shield.
Detach the stabilizer bar connecting links
from the suspension struts (right-hand
side shown).

7. Remove the radiator support brackets re-

taining bolts (left-hand side shown).
Vehicles with 1.8L, 2.0L or diesel engine
10. Remove the exhaust flexible pipe. For
additional information, refer to Section
309-00.
Vehicles with 2.5L engine
11. Remove the dual converter Y-pipe. For
additional information, refer to Section
309-00.

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204-01-16 Front Suspension 204-01-16

REMOVAL AND INSTALLATION (Continued)

All vehicles 15. Detach the radiator cooling fan wiring
12. Remove the engine rear support insula- harness from the subframe.
tor.

Vehicles with xenon headlamps

13. Disconnect the catalyst monitor sensor 16. Detach the headlamp leveling sensor wir-
electrical connector. ing harness from the subframe.

14. Detach the catalyst monitor sensor wiring All vehicles

harness from the subframe. 17. Using two suitable wooden blocks and
suitable transmission jack, support the
subframe.

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204-01-17 Front Suspension 204-01-17

REMOVAL AND INSTALLATION (Continued)

18. Remove the subframe rear retaining bolts 21. NOTE: Use a 5 mm Allen key to prevent the
and the subframe rear bracket retaining ball joint from rotating.
bolts (right-hand side shown).
Remove the stabilizer bar connecting
links (left-hand side shown).

19. Remove the subframe front retaining

bolts (right-hand side shown).
22. Detach the steering gear from the
subframe.
• Using cable ties, support the steering gear.

20. CAUTION: Lower the subframe

uniformly, to prevent the lower arm
hydro-bushings from damage. 23. Remove the stabilizer bar (two bolts each
Using the transmission jack, lower the side).
subframe approximately 150 mm.

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204-01-18 Front Suspension 204-01-18

REMOVAL AND INSTALLATION (Continued)

Installation 4. Using the special tool and a suitable
washer, align the subframe.
All vehicles 1. Insert the washer, with inside diameter 22
1. Install the stabilizer bar (two bolts each mm, outside diameter 44 mm and height 5
side). mm, into the subframe above the lower
alignment hole.
2. Insert the alignment pins through the
subframe alignment holes and the washer.
3. Slide the locking plates on top of the
washer and into the groove of the tool and
tighten the alignment pin sleeve.

2. Attach the steering gear to the subframe.

5. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe front retaining bolts
(right-hand side shown).

3. NOTE: Use a 5 mm Allen key to prevent the

ball joint from rotating.
Install the stabilizer bar connecting links
(left-hand side shown).

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204-01-19 Front Suspension 204-01-19

REMOVAL AND INSTALLATION (Continued)

All vehicles
6. CAUTION: While tightening the 9. Attach the radiator cooling fan wiring har-
subframe retaining bolts, make sure ness to the subframe.
the subframe does not move.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
(right-hand side shown).
• Lower and remove the transmission jack.

10. Attach the catalyst monitor sensor wiring

harness to the subframe.

7. Remove the special tools.

11. Connect the catalyst monitor sensor elec-

trical connector.

Vehicles with xenon headlamps

8. Attach the headlamp leveling sensor wir-
ing harness to the subframe.

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204-01-20 Front Suspension 204-01-20

REMOVAL AND INSTALLATION (Continued)

12. Install the engine rear support insulator. 16. Install the coolant hose support bracket.

Vehicles with 2.5L engine 17. Install the radiator support brackets (left-
13. Install the dual converter Y-pipe. For hand side shown).
additional information, refer to Section
309-00.
Vehicles with 1.8L, 2.0L or diesel engine
14. Install the exhaust flexible pipe. For
additional information, refer to Section
309-00.
All vehicles
15. NOTE: Use a 5 mm Allen key to prevent the
ball joint from rotating.
Attach the stabilizer bar connecting links
to the suspension struts (right-hand side
shown).

18. Install the splash shield.

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204-01-21 Front Suspension 204-01-21

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine 22. WARNING: Install a new steering

19. Install the engine undershield. column to steering column flexible
coupling retaining bolt. Failure to
follow this instruction may result in
personal injury.
Connect the steering column shaft to the
steering column flexible coupling.
1. Rotate the clamp plate.
2. Install the retaining bolt.

All vehicles
20. Install the front wheels and tires. For
additional information, refer to Section
204-04.
21. Remove the radiator support pins (left-
hand side shown).

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204-01-22 Front Suspension 204-01-22

REMOVAL AND INSTALLATION

Stabilizer Bar Bushing (14 754 0)

2. Using a suitable vise fitted with vise jaw
protectors, install the stabilizer bar
clamps.
General Equipment
1. Support the stabilizer bar bushing with a
Vise metal bar of 10 mm depth, 30 mm wide
Vise jaw protectors and 100 mm long.
2. Install the clamps.

Removal
1. Remove the stabilizer bar. For additional
information, refer to Stabilizer Bar in this
section.
2. Remove the stabilizer bar bushings.
1. Remove the clamps.
2. Remove the bushings.

3. Install the stabilizer bar. For additional

information, refer to Stabilizer Bar in this
section.

Installation
1. CAUTION: The stabilizer bar bushings
must be located correctly on the flats
of the stabilizer bar.
Install the stabilizer bar bushings.

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204-01-23 Front Suspension 204-01-23

REMOVAL AND INSTALLATION

Wheel Knuckle (14 343 0)

Removal
Special Tool(s)
All vehicles
Lever, Wheel Knuckle
204-159 (14-039) 1. CAUTION: Use a socket to loosen the
wheel hub retaining nut to prevent
damage.
Loosen the wheel hub retaining nut.
Installer, Halfshaft
204-161 (14-041)

Alignment Pins, Subframe

205-316 (15-097A)

Separator, Ball Joint

211-020 (13-006)
2. Remove the strut and spring assembly top
mount brace cover.

General Equipment
Transmission jack
Three leg puller

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204-01-24 Front Suspension 204-01-24

REMOVAL AND INSTALLATION (Continued)

the piston rod from rotating. 6. CAUTION: Leave the tie-rod end
retaining nut in place to protect the
Loosen the strut and spring assembly top
ball joint stud.
mount nut by five turns.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Loosen the tie-rod end retaining nut.

4. Remove the wheel and tire. For

additional information, refer to Section
204-04.
5. Disconnect the front wheel speed sensor 7. CAUTION: Protect the ball joint seal
electrical connector from the front wheel using a soft cloth to prevent damage.
speed sensor.
Using the special tool, detach the tie-rod
end from the wheel knuckle.
1. Release the tie-rod end.
2. Remove the tie-rod end retaining nut.
• Discard the retaining nut.

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204-01-25 Front Suspension 204-01-25

REMOVAL AND INSTALLATION (Continued)

8. CAUTION: Suspend the brake caliper 11. NOTE: Only one side of the subframe needs
and anchor plate to prevent load being to be lowered to detach the lower arm ball joint
placed on the brake hose. from the wheel knuckle.
Detach the brake caliper and anchor plate Using a suitable transmission jack,
from the wheel knuckle. support the side of the subframe to be
lowered.

Vehicles with diesel engine

9. Remove the engine undershield. 12. Remove the subframe rear retaining bolt
and the subframe rear bracket retaining
bolts, on the side the wheel knuckle is
being removed (right-hand side shown).

All vehicles
10. Detach the splash shield from the sub-
frame.
13. Loosen the subframe rear retaining bolt
and the subframe rear bracket retaining
bolts, on the opposite side, by five turns.

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204-01-26 Front Suspension 204-01-26

REMOVAL AND INSTALLATION (Continued)

14. Remove the subframe front retaining bolt, 17. CAUTION: To prevent damage to the
on the side the wheel knuckle is being lower arm hydro-bushing, make sure
removed (right-hand side shown). the subframe is lowered before
detaching the lower arm ball joint from
the wheel knuckle.
Remove the lower arm ball joint to wheel
knuckle pinch bolt and nut.

15. Loosen the subframe front retaining bolt,

on the opposite side, by five turns.
16. Lower the subframe to gain access to the
lower arm rear retaining bolt.

18. CAUTION: Protect the ball joint seal

using a soft cloth to prevent damage.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

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204-01-27 Front Suspension 204-01-27

REMOVAL AND INSTALLATION (Continued)

19. CAUTION: The wheel hub retaining 22. CAUTION: Support the halfshaft. The
nut can be re-used four times, mark inner joint must not be bent more than
the retaining nut. 18 degrees. The outer joint must not
be bent more than 45 degrees.
Remove the wheel hub retaining nut.
Using a suitable three leg puller, detach
the wheel hub from the halfshaft.

20. Remove the brake disc.

21. Remove the wheel knuckle to suspension
strut pinch bolt. 23. Using the special tool, remove the wheel
knuckle.

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204-01-28 Front Suspension 204-01-28

REMOVAL AND INSTALLATION (Continued)

4. CAUTION: Make sure the heat shield is

Installation installed to prevent damage to the ball
joint.
All vehicles Install the heat shield.
1. Install the wheel knuckle.

5. CAUTION: The lower arm pinch bolt

2. CAUTION: Make sure the halfshaft is must be installed from the rear of the
completely installed into the wheel wheel knuckle.
hub.
Attach the lower arm ball joint to the wheel
Using the special tool, attach the wheel knuckle.
hub to the halfshaft.

3. Install the brake disc.

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204-01-29 Front Suspension 204-01-29

REMOVAL AND INSTALLATION (Continued)

6. Using the special tool and a suitable 8. Tighten the subframe rear retaining bolt
washer, align the subframe. and the subframe bracket retaining bolts,
1. Insert the washer, with inside diameter 22 on the opposite side (left-hand side
mm, outside diameter 44 mm and height 5 shown).
mm, into the subframe above the lower
alignment hole.
2. Insert the alignment pin through the
subframe alignment holes and the washer.
3. Slide the locking plates on top of the
washer and into the groove of the tool and
tighten the alignment pin sleeve.

9. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe front retaining bolt, on
the side the wheel knucle was installed
(right-hand side shown).

7. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolt and
the subframe bracket retaining bolts, on
the side the wheel knuckle was installed
(right-hand side shown).

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204-01-30 Front Suspension 204-01-30

REMOVAL AND INSTALLATION (Continued)

10. Tighten the subframe front retaining bolt, Vehicle with diesel engine
on opposite side (left-hand side shown). 13. Install the engine undershield.
• Lower and remove the transmission jack.

All vehicles
11. Remove the special tools. 14. Attach the brake caliper and anchor plate
to the wheel knuckle.

12. Attach the splash shield to the subframe.

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204-01-31 Front Suspension 204-01-31

REMOVAL AND INSTALLATION (Continued)

15. WARNING: Install a new tie-rod end 17. Connect the front wheel speed sensor
retaining nut. Failure to follow this electrical connector to the front wheel
instruction may result in personal speed sensor.
injury.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Attach the tie-rod end to the wheel
knuckle.

18. Install the wheel and tire. For additional

information, refer to Section 204-04.
19. Tighten the wheel hub retaining nut.

16. CAUTION: The wheel hub retaining

nut can be re-used four times, inspect
the markings on the retaining nut and
install a new retaining nut if
necessary.
With the aid of another technician, apply
the brakes and pre load the wheel bear-
ing by installing the wheel hub retaining
nut.

20. CAUTION: Use an Allen key to

prevent the piston rod from turning.
Tighten the strut and spring assembly
top mount nut.

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204-01-32 Front Suspension 204-01-32

REMOVAL AND INSTALLATION (Continued)

21. Install the strut and spring assembly top
mount brace cover.

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204-01-33 Front Suspension 204-01-33

REMOVAL AND INSTALLATION

Strut and Spring Assembly (14 781 0)

3. NOTE: Use a 5 mm Allen key to prevent the
ball joint from rotating.
Special Tool(s) Detach the stabilizer bar connecting link
from the suspension strut.
Lever, Wheel Knuckle
204-159 (14-039)

Alignment Pins, Subframe

205-316 (15-097A)

General Equipment
Transmission jack
4. CAUTION: Suspend the brake caliper
and anchor plate to prevent load being
Removal placed on the brake hose.
Detach the brake caliper and anchor plate
All vehicles from the wheel knuckle.
1. Remove the wheel and tire. For additional
information, refer to Section 204-04.
2. Detach the brake hose support bracket
from the suspension strut.

Vehicles with diesel engine

5. Remove the engine undershield.

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204-01-34 Front Suspension 204-01-34

REMOVAL AND INSTALLATION (Continued)

8. Remove the subframe rear retaining bolt
All vehicles
and the subframe rear bracket retaining
6. Detach the splash shield from the sub-
bolts, on the side the strut and spring as-
frame.
sembly is being removed (right-hand side
shown).

7. NOTE: Only one side of the subframe needs to

be lowered to detach the lower arm ball joint
9. Loosen the subframe rear retaining bolt
from the wheel knuckle.
and the subframe rear bracket retaining
Using a suitable transmission jack, sup- bolts, on the opposite side, by five turns.
port the side of the subframe to be low- 10. Remove the subframe front retaining bolt,
ered. on the side the strut and spring assembly
is being removed (right-hand side
shown).

11. Loosen the subframe front retaining bolt,

on the opposite side, by five turns.

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204-01-35 Front Suspension 204-01-35

REMOVAL AND INSTALLATION (Continued)

12. Lower the subframe. 14. CAUTION: Protect the ball joint seal
using a soft cloth to prevent damage.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

13. CAUTION: To prevent damage to the

lower arm hydro-bushing, make sure
the subframe is lowered before
detaching the lower arm ball joint from
the wheel knuckle.
15. Remove the wheel knuckle to suspension
Remove the lower arm ball joint to wheel strut pinch bolt.
knuckle pinch bolt and nut.

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204-01-36 Front Suspension 204-01-36

REMOVAL AND INSTALLATION (Continued)

16. CAUTION: Support the halfshaft. The 18. CAUTION: With the aid of another
inner joint must not be bent more than technician, support the strut and
18 degrees. The outer joint must not spring assembly.
be bent more than 45 degrees.
Remove the strut and spring assembly.
Using the special tool, detach the wheel
knuckle from the suspension strut.

Installation
17. Remove the strut and spring assembly
top mount brace cover. All vehicles
1. NOTE: Make sure the arrow and the white line
on the top mount are pointing to the front of
the vehicle.
Install the strut and spring assembly.

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204-01-37 Front Suspension 204-01-37

REMOVAL AND INSTALLATION (Continued)

2. Tighten the strut and spring assembly top 5. CAUTION: Make sure the heat shield is
mount retaining nuts. installed to prevent damage to the ball
joint.
Install the heat shield.

3. Install the strut and spring assembly top

mount brace cover.

6. CAUTION: The lower arm pinch bolt

must be installed from the rear of the
wheel knuckle.
Attach the lower arm ball joint to the wheel
knuckle.

4. Attach the wheel knuckle to the suspen-

sion strut.

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204-01-38 Front Suspension 204-01-38

REMOVAL AND INSTALLATION (Continued)

7. Using the special tool and a suitable 9. Tighten the subframe rear retaining bolt
washer, align the subframe. and the subframe bracket retaining bolts,
1. Insert the washer, with inside diameter 22 on the opposite side (left-hand side
mm, outside diameter 44 mm and height 5 shown).
mm, into the subframe above the lower
alignment hole.
2. Insert the alignment pin through the
subframe alignment holes and the washer.
3. Slide the locking plates on top of the
washer and into the groove of the tool and
tighten the alignment pin sleeve.

10. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe front retaining bolt,
on the side the strut and spring assembly
was installed (right-hand side shown).

8. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolt and
the subframe bracket retaining bolts, on
the side the strut and spring assembly was
installed (right-hand side shown).

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204-01-39 Front Suspension 204-01-39

REMOVAL AND INSTALLATION (Continued)

11. Tighten the subframe front retaining bolt, Vehicles with diesel engine
on the opposite side (left-hand side 14. Install the engine undershield.
shown).
• Lower and remove the transmission jack.

All vehicles
15. Attach the brake caliper and anchor plate
12. Remove the special tools. to the wheel knuckle.

13. Attach the splash shield to the subframe. 16. NOTE: Use a 5 mm Allen key to prevent the
ball joint from rotating.
Attach the stabilizer bar connecting link
to the suspension strut.

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204-01-40 Front Suspension 204-01-40

REMOVAL AND INSTALLATION (Continued)

17. Attach the brake hose support bracket to
the suspension strut.

18. Install the wheel and tire. For additional

information, refer to Section 204-04.

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204-01-41 Front Suspension 204-01-41

DISASSEMBLY AND ASSEMBLY

Strut and Spring Assembly (14 783 4)

DISASSEMBLY AND ASSEMBLY

2. CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Special Tool(s) Loosen the thrust bearing retaining nut.
Compressor, Coil Spring
204-167 (14-042)

Adaptors for 204-167

204-167-01 (14-042-01)

Disassembly
1. WARNING: The spring is under
extreme tension; care must be taken
at all times. Failure to follow this
instruction may result in personal
injury.
Using the special tools, compress the
spring.

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204-01-42 Front Suspension 204-01-42

DISASSEMBLY AND ASSEMBLY (Continued)

3. Disassemble the strut and spring Assembly
assembly.
1. Remove the thrust bearing retaining nut. 1. CAUTION: The ends of the spring must
locate correctly in the spring seats.
2. Remove the top mount.
3. Remove the thrust bearing. To assemble, reverse the disassembly
procedure.
4. Remove the spring seat.
5. Remove the spring.
6. Remove the bump stop.
7. Remove the boot.

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204-02-1 Rear Suspension 204-02-1

SECTION 204-02 Rear Suspension

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 204-02-2

DESCRIPTION AND OPERATION

Rear Suspension............................................................................................................... 204-02-3

DIAGNOSIS AND TESTING

Rear Suspension............................................................................................................... 204-02-4

REMOVAL AND INSTALLATION

Wheel Hub.................................................................................................... (15 373 0) 204-02-5

Front Lower Arm — 4-Door/5-Door............................................................... (15 690 0) 204-02-7
Rear Lower Arm — 4-Door/5-Door ............................................................... (15 693 0) 204-02-11
Rear Lower Arm — Wagon........................................................................... (15 693 0) 204-02-13
Tie Bar — 4-Door/5-Door.............................................................................. (15 765 0) 204-02-16
Wheel Knuckle — 4-Door/5-Door ...................................................................................... 204-02-18
Wheel Knuckle — Wagon.................................................................................................. 204-02-19
Shock Absorber — Wagon ........................................................................... (15 791 0) 204-02-22
Strut and Spring Assembly — 4-Door/5-Door ............................................... (15 781 0) 204-02-23
Spring — Wagon .......................................................................................... (15 621 0) 204-02-24
Crossmember — 4-Door/5-Door........................................................................................ 204-02-25
Crossmember — Wagon ................................................................................................... 204-02-33

DISASSEMBLY AND ASSEMBLY

Strut and Spring Assembly ................................................................................................ 204-02-35

08/2002 2003.0 Mondeo

204-02-2 Rear Suspension 204-02-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Stabilizer bar connecting link retaining nuts 48 35 –
Stabilizer bar clamp retaining bolts 25 18 –
Stabilizer bar connecting link to lower arm retain- 48 35 –
ing nut (wagon)
Crossmember retaining bolts 120 89 –
Upper arm to wheel knuckle retaining bolt (Wagon) 120 89 –
Upper arm to crossmember retaining bolt (Wagon) 84 62 –
Front lower arm to crossmember retaining nut 103 76 –
Front lower arm to wheel knuckle retaining bolt 84 62 –
(Wagon)
Front lower arm to wheel knuckle retaining bolt (4- 120 89 –
door and 5-door)
Rear lower arm to wheel knuckle retaining bolt 84 62 –
(Wagon)
Rear lower arm to wheel knuckle retaining bolt (4- 120 89 –
door and 5-door)
Rear lower arm to crossmember cam retaining nut 103 76 –
Wheel speed sensor retaining bolt 7 – 62
Brake caliper anchor plate retaining bolt 80 59 –
Wheel knuckle pinch bolt 85 63 –
Wheel hub retaining bolts 70 52 –
Wheel knuckle to bracket retaining nut (Wagon) 103 76 –
Wheel knuckle bracket retaining bolts (Wagon) 120 89 –
Tie-bar to wheel knuckle retaining bolt (4-door and 103 76 –
5-door)
Tie-bar to bracket retaining nut 103 76 –
Tie-bar bracket retaining bolts 120 89 –
Strut and spring assembly retaining bolts 25 18 –
Strut and spring assembly thrust bearing retaining 58 43 –
nut
Shock absorber upper mounting retaining bolt 84 62 –
(Wagon)
Shock absorber lower mounting retaining bolt 120 89 –
(Wagon)
Catalytic converter to front muffler pipe nuts 46 34 –
Exhaust flexible pipe to front muffler pipe nuts 46 34 –

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204-02-3 Rear Suspension 204-02-3

DESCRIPTION AND OPERATION

Rear Suspension
DESCRIPTION AND OPERATION

Information not available at this time

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204-02-4 Rear Suspension 204-02-4

DIAGNOSIS AND TESTING

Rear Suspension
DIAGNOSIS AND TESTING

REFER to Section 204-00.

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204-02-5 Rear Suspension 204-02-5

REMOVAL AND INSTALLATION

Wheel Hub (15 373 0)

REMOVAL AND INSTALLATION

Removal 4. Detach the rear wheel speed sensor from

the wheel hub.
1. Remove the wheel and tire. For additional
information, refer to Section 204-04.
2. Detach the parking brake cable from the
brake caliper lever.
1. Push the caliper lever.
2. Detach the parking brake cable.

5. CAUTION: Suspend the brake caliper

and anchor plate to prevent load being
placed on the brake hose.
Detach the brake caliper and anchor plate
from the wheel knuckle.
3. Detach the parking brake cable from the
brake caliper.
1. Depress the locking tangs.
2. Detach the cable from the brake caliper.

6. Remove the brake disc.

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204-02-6 Rear Suspension 204-02-6

REMOVAL AND INSTALLATION (Continued)

7. Remove the wheel hub.

Installation
1. To install, reverse the removal procedure.

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204-02-7 Rear Suspension 204-02-7

REMOVAL AND INSTALLATION

Front Lower Arm — 4-Door/5-Door (15 690 0)

Vehicles with 1.8L, 2.0L or diesel engine
4. NOTE: Support the front and rear muffler
Special Tool(s) assembly with a suitable axle stand.

Alignment Pins, Subframe Detach the exhaust system from the rear
exhaust hanger insulator.
205-316 (15-097A)

General Equipment
Transmission jack
Axle stand

Removal
All vehicles
1. Remove the wheel and tire. For additional Vehicles with 2.5L engine
information, refer to Section 204-04.
5. NOTE: Support the front and rear muffler
Vehicles with xenon headlamps assembly with a suitable axle stand.
2. Remove the headlamp leveling sensor. For
additional information, refer to Section Detach the exhaust system from both rear
417-01. exhaust hanger insulators (left-hand
shown, right-hand similar).
All vehicles
3. Detach the exhaust system from the inter-
mediate exhaust hanger insulator.

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204-02-8 Rear Suspension 204-02-8

REMOVAL AND INSTALLATION (Continued)

All vehicles 10. Remove the front lower arm.
6. Using suitable wooden blocks and a suit-
able transmission jack, support the
crossmember.

Installation
7. Remove the crossmember retaining bolts All vehicles
(two bolts each side).
NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.
1. NOTE: Do not fully tighten the front lower arm
retaining nut and bolt at this stage.
Install the front lower arm.

8. Lower the crossmember to gain access to

the front lower arm retaining nut and bolt.
9. Detach the front lower arm from the wheel
knuckle.

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204-02-9 Rear Suspension 204-02-9

REMOVAL AND INSTALLATION (Continued)

2. NOTE: Do not fully tighten the front lower arm

Vehicles with 1.8L, 2.0L or diesel engine
retaining bolt at this stage.
5. Attach the exhaust system to the rear ex-
Attach the front lower arm to the wheel haust hanger insulator.
knuckle.

Vehicles with 2.5L engine

3. Using the special tool, align the 6. Attach the exhaust system to both rear ex-
crossmember. haust hanger insulators (left-hand shown,
1. Insert the alignment pins through the right-hand similar).
crossmember alignment holes.
2. Slide the locking plate into the groove and
tighten the alignment pin sleeve.

All vehicles
7. Attach the exhaust system to the interme-
diate exhaust hanger insulator.
4. Install the crossmember (two bolts each
side).

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204-02-10 Rear Suspension 204-02-10

REMOVAL AND INSTALLATION (Continued)

Vehicles with xenon headlamps
8. Install the headlamp leveling sensor. For
additional information, refer to Section
417-01.
All vehicles
9. Install the wheel and tire. For additional
information, refer to Section 204-04.
10. Tighten the front lower arm to wheel
knuckle retaining bolt.

11. Tighten the front lower arm to cross-

member retaining nut.

Vehicles with xenon headlamps

12. Initialize the headlamp leveling system
using WDS.

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204-02-11 Rear Suspension 204-02-11

REMOVAL AND INSTALLATION

Rear Lower Arm — 4-Door/5-Door (15 693 0)

Removal 1. NOTE: Do not fully tighten the rear lower arm

adjustment cam nut at this stage.
1. Remove the wheel and tire. For additional
information, refer to Section 204-04. Attach the rear lower arm to the cross-
member.
2. Detach the rear lower arm from the wheel
knuckle.

2. NOTE: Do not fully tighten the rear lower arm

to wheel knuckle retaining bolt at this stage.
3. Remove the rear lower arm.
Install the rear lower arm.

Installation 3. Install the wheel and tire. For additional

information, refer to Section 204-04.
NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.

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204-02-12 Rear Suspension 204-02-12

REMOVAL AND INSTALLATION (Continued)

4. Tighten the rear lower arm to wheel
knuckle retaining bolt.

5. Check the toe setting and adjust as

necessary. For additional information,
refer to Section 204-00.
6. Tighten the rear lower arm adjustment cam
nut.

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204-02-13 Rear Suspension 204-02-13

REMOVAL AND INSTALLATION

Rear Lower Arm — Wagon (15 693 0)

5. NOTE: The spacer must be positioned exactly
as shown.
General Equipment Using a suitable transmission jack, raise
the rear lower arm to the suspension
Transmission jack design height setting.
1. Position the spacer.
2. Raise the rear lower arm.
Removal
All vehicles
1. Remove the wheel and tire. For
additional information, refer to Section
204-04.
2. Fabricate a 20 mm wide by 186 mm long
spacer.

Vehicles with xenon headlamps

6. NOTE: The headlamp leveling sensor wiring
harness is attached to the left-hand rear lower
arm.
Detach the headlamp leveling sensor wir-
ing harness from the rear lower arm.

3. Detach the stabilizer bar from the rear

lower arm.

4. Remove the spring. For additional

information, refer to Spring-Wagon in this
section.

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204-02-14 Rear Suspension 204-02-14

REMOVAL AND INSTALLATION (Continued)

All vehicles 1. NOTE: Do not fully tighten the rear lower arm
7. Detach the rear lower arm from the wheel adjustment cam nut at this stage.
knuckle.
Attach the rear lower arm to the cross-
member.

8. Remove the rear lower arm.

2. NOTE: Do not fully tighten the rear lower arm
to wheel knuckle retaining bolt at this stage.
Install the rear lower arm.

Installation
All vehicles
NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.

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204-02-15 Rear Suspension 204-02-15

REMOVAL AND INSTALLATION (Continued)

Vehicles with xenon headlamps 8. Tighten the rear lower arm to wheel
3. NOTE: The headlamp leveling sensor wiring knuckle retaining bolt (wheel and tire
harness is attached to the left-hand rear lower shown removed for clarity).
arm.
Attach the headlamp leveling sensor wir-
ing harness to the rear lower arm.

9. Check the toe setting and adjust as

necessary. For additional information,
refer to Section 204-00.
10. Tighten the rear lower arm adjustment
All vehicles
cam nut.
4. Lower the suspension from the design
height setting.
5. Install the spring. For additional
information, refer to Spring-Wagon in this
section.
6. Attach the stabilizer bar to the rear lower
arm.

7. Install the wheel and tire. For additional

information, refer to Section 204-02.

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204-02-16 Rear Suspension 204-02-16

REMOVAL AND INSTALLATION

Tie Bar — 4-Door/5-Door (15 765 0)

Removal Vehicles with xenon headlamps

All vehicles 4. NOTE: The headlamp leveling sensor wiring
1. Raise and support the vehicle. For harness is attached to the left-hand tie bar.
additional information, refer to Section Detach the headlamp leveling sensor wir-
100-02. ing harness from the tie bar.
2. Remove the tie bar bracket cover.

All vehicles
3. Detach the intermediate exhaust hanger 5. Detach the parking brake cable from the tie
insulator from the tie bar (if equipped). bar.

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204-02-17 Rear Suspension 204-02-17

REMOVAL AND INSTALLATION (Continued)

6. Detach the rear wheel speed sensor wiring 9. Remove the tie bar bracket from the tie
harness from the tie bar. bar.

7. Detach the tie bar from the wheel knuckle.

Installation
1. NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.
To install, reverse the removal procedure.

8. Remove the tie bar.

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204-02-18 Rear Suspension 204-02-18

REMOVAL AND INSTALLATION

Wheel Knuckle — 4-Door/5-Door

Removal
1. Remove the wheel hub. For additional 5. Remove the wheel knuckle.
information, refer to Wheel Hub in this
section.
2. Detach the front and rear lower arms from
the wheel knuckle.

Installation
1. NOTE: Final tightening of the rear suspension
3. Detach the tie bar from the wheel knuckle components should be carried out when the
vehicle weight is on the road wheels.
To install, reverse the removal procedure.

4. Detach the stabilizer bar connecting link

from the stabilizer bar.

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204-02-19 Rear Suspension 204-02-19

REMOVAL AND INSTALLATION

Wheel Knuckle — Wagon

4. Pull the parking brake cable through the
wheel knuckle.
General Equipment
Transmission jack

Removal
All vehicles
1. Remove the wheel hub. For additional
information, refer to Wheel Hub in this
section.
Vehicles with xenon headlamps
2. NOTE: The headlamp leveling sensor wiring
harness is attached to the left-hand wheel
knuckle. 5. Remove the wheel knuckle bracket cover.
Detach the headlamp leveling sensor wir-
ing harness from the wheel knuckle.

6. Detach the parking brake cable from the

wheel knuckle.
All vehicles
3. Detach the wheel speed sensor wiring
harness from the wheel knuckle.

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204-02-20 Rear Suspension 204-02-20

REMOVAL AND INSTALLATION (Continued)

7. Detach the exhaust hanger insulator from 11. NOTE: The spacer must be positioned
the wheel knuckle (if equipped). exactly as shown.
Using a suitable transmission jack, raise
the rear lower arm to the suspension
design height setting.
1. Position the spacer.
2. Raise the rear lower arm.

8. Fabricate a 20 mm wide by 186 mm long

spacer.

12. Detach the front lower arm from the

wheel knuckle.

9. Detach the stabilizer bar from the rear

lower arm.

13. Detach the upper arm from the wheel

knuckle.

10. Remove the spring. For additional

information, refer to Spring-Wagon in this
section.

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204-02-21 Rear Suspension 204-02-21

REMOVAL AND INSTALLATION (Continued)

14. Detach the shock absorber from the 17. Remove the wheel knuckle bracket from
wheel knuckle. the wheel knuckle.

15. Detach the rear lower arm from the wheel

knuckle. Installation
1. NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.
To install, reverse the removal procedure.

16. CAUTION: With the aid of another

technician, support the wheel knuckle.
Remove the wheel knuckle.

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204-02-22 Rear Suspension 204-02-22

REMOVAL AND INSTALLATION

Shock Absorber — Wagon (15 791 0)

All vehicles
General Equipment 2. NOTE: Final tightening of the shock absorber
should be carried out when the vehicle weight
Transmission jack is on the road wheels.
Install the shock absorber.
Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Using a suitable transmission jack,
support the lower arm.
3. Remove the shock absorber.
1. Remove the lower mounting bolt.
2. Remove the upper mounting bolt.

3. Lower vehicle.

Installation
Vehicle with load levelling shock absorbers
1. NOTE: Make sure the tab on the shock
absorber top mount is pointing outwards.
Install the shock absorber.

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204-02-23 Rear Suspension 204-02-23

REMOVAL AND INSTALLATION

Strut and Spring Assembly — 4-Door/5-Door (15 781 0)

4. Remove the strut and spring assembly.

General Equipment
Trolley jack

Removal
1. Remove the wheel knuckle. For additional
information, refer to Wheel Knuckle in this
section.
2. Detach the stabilizer bar connecting link
from the suspension strut.

Installation
1. To install, reverse the removal procedure.

3. Using a suitable trolley jack, detach the

suspension strut from the crossmember
ledge.
1. Raise the suspension strut.
2. Move the suspension strut away from the
crossmember ledge and lower the suspen-
sion strut.

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204-02-24 Rear Suspension 204-02-24

REMOVAL AND INSTALLATION

Spring — Wagon (15 621 0)

3. WARNING: As the spring is under
extreme tension care must be taken at
Special Tool(s) all times. Failure to follow this
instruction may result in personal
Compressor, Coil Spring injury.
204-167 (14-042) Remove the spring (wheel and tire
removed for clarity).
1. Detach the bump stop from the
crossmember.
Adapters for 204-167 2. Remove the spring and bump stop.
204-215 (15-111)

Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Using the special tools, compress the
spring (wheel and tire removed for clarity).

Installation
1. To install, reverse the removal procedure.

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204-02-25 Rear Suspension 204-02-25

REMOVAL AND INSTALLATION

Crossmember — 4-Door/5-Door
Vehicles with 2.5L engine
4. Detach the catalytic converter from the
front muffler pipe.
Special Tool(s)
• Discard the gasket and nuts.
Alignment Pins, Subframe
205-316 (15-097-A)

General Equipment
Trolley jack
Transmission jack
Securing strap

Name Specification
Vehicles with diesel engine
Anti-seize grease SAM-1C107-A
5. CAUTION: Over bending of the exhaust
flexible pipe may cause damage
Removal resulting in failure.
Support the exhaust flexible pipe with a
All vehicles
support wrap or suitable splint.
1. Remove the wheels and tires. For
additional information, refer to Section
204-04.
Vehicles with xenon headlamps
2. Remove the headlamp leveling sensor.
For additional information, refer to Section
417-01.
Vehicles with 1.8L or 2.0L engine
3. Detach the catalytic converter from the
front muffler pipe.
• Discard the gasket and nuts.

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204-02-26 Rear Suspension 204-02-26

REMOVAL AND INSTALLATION (Continued)

6. Detach the exhaust flexible pipe from the Vehicles with 1.8L, 2.0L or diesel engine
front muffler pipe. 9. Remove the front and rear muffler
• Discard the sealing ring and nuts. assembly.
• Detach the muffler from the rear exhaust
hanger insulator.

All vehicles
7. Detach the front and rear muffler assembly
from the front exhaust hanger insulator. Vehicles with 2.5L engine
10. Remove the front and rear muffler
assembly.
• Detach the rear mufflers from the rear ex-
haust hanger insulators (left-hand side
shown).

8. NOTE: Support the front and rear muffler with

a suitable axle stand.
Detach the front and rear muffler assembly
from the intermediate exhaust hanger in-
sulator.

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204-02-27 Rear Suspension 204-02-27

REMOVAL AND INSTALLATION (Continued)

All vehicles 14. Detach the parking brake cable from the
11. Detach the stabilizer bar connecting link brake caliper on both sides.
from the stabilizer bar on both sides. 1. Depress the locking tangs.
2. Detach the brake cable from the brake
caliper.

12. Disconnect the rear wheel speed sensor

electrical connector from the rear wheel
speed sensor on both sides.
15. CAUTION: Suspend the brake caliper
and anchor plate to prevent load being
placed on the brake hoses.
Detach the brake caliper and anchor plate
from the wheel knuckle on both sides.

13. Detach the parking brake cable from the

brake caliper lever on both sides.
1. Push the caliper lever.
2. Detach the parking brake cable.
16. Detach the front and rear lower arm from
the wheel knuckle on both sides.

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204-02-28 Rear Suspension 204-02-28

REMOVAL AND INSTALLATION (Continued)

20. Remove the crossmember (two bolts
17. Detach the tie-bar from the wheel knuckle each side).
on both sides.

18. Using a suitable trolley jack, detach the

suspension strut from the crossmember Installation
ledge on both sides.
All vehicles
1. Raise the suspension strut.
NOTE: Final tightening of the rear suspension
2. Move the suspension strut away from the
components should be carried out when the
crossmember ledge and lower the suspen-
vehicle weight is on the road wheels.
sion strut.
1. Using the special tools, align the
crossmember.
1. Install the special tools.
2. Install the locking plates and tighten the
sleeve.

19. WARNING: Make sure the

crossmember is secured to the
transmission jack. Failure to follow
this instruction may result in personal
injury.
Using a suitable securing strap, secure
the crossmember to the transmission
jack.

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204-02-29 Rear Suspension 204-02-29

REMOVAL AND INSTALLATION (Continued)

2. Install the crossmember (two bolts each 5. NOTE: Do not fully tighten the tie-bar retaining
side). bolts at this stage.
Attach the tie-bar to the wheel knuckle on
both sides.

3. Remove the securing straps and the

transmission jack.
4. Using a suitable trolley jack jack, attach 6. NOTE: Do not fully tighten the front and rear
the suspension strut to the crossmember lower arm retaining bolts at this stage.
ledge on both sides.
Attach the front and rear lower arms to the
1. Raise the suspension strut.
wheel knuckle on both sides.
2. Move the suspension strut towards the
crossmember ledge and lower the suspen-
sion strut onto the ledge.

7. Attach the brake caliper and anchor plate

to the wheel knuckle on both sides.

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204-02-30 Rear Suspension 204-02-30

REMOVAL AND INSTALLATION (Continued)

8. Connect the rear wheel speed sensor elec- 11. Attach the stabilizer bar connecting link
trical connector to the rear wheel speed to the stabilizer bar on both sides.
sensor on both sides.

Vehicles with 2.5L engine

9. Attach the parking brake cable to the brake 12. Install the front and rear muffler
caliper on both sides. assembly.
• Attach the rear mufflers to the rear exhaust
hanger insulators (left-hand side shown).

10. Attach the parking brake cable to the

brake caliper lever on both sides.
1. Push the caliper lever. Vehicles with 1.8L, 2.0L or diesel engine
2. Attach the parking brake cable. 13. Install the front and rear muffler
assembly.
• Attach the muffler to the rear exhaust
hanger insulator.

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204-02-31 Rear Suspension 204-02-31

REMOVAL AND INSTALLATION (Continued)

All vehicles
17. Remove the exhaust wrap or splint.
14. Attach the front and rear muffler assem-
bly to the intermediate exhaust hanger Vehicles with 2.5L engine
insulator. 18. NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install a new gasket and nuts.
Attach the catalytic converter to the front
muffler pipe.

15. Attach the front and rear muffler assem-

bly to the front exhaust hanger insulator.

Vehicles with 1.8L or 2.0L engine

19. NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install a new gasket and nuts.
Attach the catalytic converter to the front
muffler pipe.

Vehicles with diesel engine

16. NOTE: Coat the front muffler pipe studs with
anti-seize grease.
NOTE: Install a new sealing ring and nuts.
Attach the exhaust flexible pipe to the
front muffler pipe.

Vehicles with xenon headlamps

20. Install the headlamp leveling sensor. For
additional information, refer to Section
417-01.
All vehicles
21. Install the wheels and tires. For
additional information, refer to Section
204-04.

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204-02-32 Rear Suspension 204-02-32

REMOVAL AND INSTALLATION (Continued)

22. Tighten the tie-bar to wheel knuckle re-
taining bolt on both sides.

23. Tighten the front and rear lower arm to

wheel knuckle retaining bolts on both
sides.

24. Check the toe setting and adjust as

necessary. For additional information,
refer to Section 204-00.
Vehicles with xenon headlamps
25. Initialize the headlamp leveling system
using WDS.

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204-02-33 Rear Suspension 204-02-33

REMOVAL AND INSTALLATION

Crossmember — Wagon
4. Remove the rear lower arms.

General Equipment
Transmission jack
Securing strap

Removal
All vehicles
1. Remove the wheel knuckles. For
additional information, refer to Wheel
Knuckle-Wagon in this section.
Vehicles with xenon headlamps
2. Remove the headlamp leveling sensor. 5. WARNING: Make sure the
For additional information, refer to Section crossmember is secured to the
417-01. transmission jack. Failure to follow
All vehicles this instruction may result in personal
injury.
3. CAUTION: Cap the brake tubes to
Using a suitable securing strap, secure the
prevent fluid loss or dirt ingress.
crossmember to the transmission jack.
Remove the brake caliper and anchor plate 6. Remove the crossmember (three bolts
assemblies. each side).
1. Disconnect the brake tube unions.
2. Remove the brake hose retaining clips.

Installation
All vehicles
1. NOTE: Final tightening of the rear suspension
components should be carried out when the
vehicle weight is on the road wheels.
To install, reverse the removal procedure.
2. Bleed the brake system. For additional
information, refer to Section 206-00.

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204-02-34 Rear Suspension 204-02-34

REMOVAL AND INSTALLATION (Continued)

3. Check the toe setting and adjust as
necessary. For additional information,
refer to Section 204-00.
Vehicles with xenon headlamps
4. Initialize the headlamp leveling system
using WDS.

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204-02-35 Rear Suspension 204-02-35

DISASSEMBLY AND ASSEMBLY

Strut and Spring Assembly

DISASSEMBLY AND ASSEMBLY

2. Disassemble the suspension unit.

1. Remove the top mount nut.
Special Tool(s) 2. Remove the retaining cup.
Spring compressor 3. Remove the top mount.
14-042 4. Remove the spring seat.
5. Remove the suspension unit.
6. Remove the gaiter.
7. Remove the bump stop.
Adaptors for 14-042
15-103

Disassembly
1. WARNING: As the spring is under
extreme tension care should be taken
at all times.
Compress the spring.

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204-02-36 Rear Suspension 204-02-36

DISASSEMBLY AND ASSEMBLY (Continued)

Assembly
1. Install the components in reverse order.

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204-04-1 Wheels and Tires 204-04-1

SECTION 204-04 Wheels and Tires

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 204-04-2

DIAGNOSIS AND TESTING

Wheels and Tires............................................................................................................... 204-04-3

Inspection and Verification ............................................................................................... 204-04-3
Symptom Chart ................................................................................................................ 204-04-4

REMOVAL AND INSTALLATION

Wheel and Tire .................................................................................................................. 204-04-7

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204-04-2 Wheels and Tires 204-04-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Wheel nuts 85 63 -

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204-04-3 Wheels and Tires 204-04-3

DIAGNOSIS AND TESTING

Wheels and Tires

DIAGNOSIS AND TESTING

- engine torque
- vehicle speed
Inspection and Verification
- engine speed
To maximize tire performance, inspect the tires – type of vibration - sensitivity: torque sensitive,
for signs of incorrect inflation and uneven wear vehicle speed sensitive or engine speed
which may indicate a need for balancing, rotation sensitive.
or suspension alignment. Tires should also be
checked frequently for cuts, stone bruises, The following explanations help isolate the
abrasions, blisters, and for objects that may have source of the vibration.
become embedded in the tread. More frequent
inspections are recommended when rapid or
Torque Sensitive
extreme temperature changes occur or when
road surfaces are rough or occasionally littered This means that the condition can be improved or
with foreign material. made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
As a further visible check of tire condition, tread
applying engine torque.
wear indicators are molded into the bottom of the
tread grooves. When these indicator bands
become visible, new tires must be installed. Vehicle Speed Sensitive
This means that the vibration always occurs at
Tire Wear Diagnosis the same vehicle speed and is not affected by
engine torque, engine speed or the transmission
Uneven wear is usually caused by either
gear selected.
excessive camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts
will cause severe `cupping' or `scalloped' tire Engine Speed Sensitive
wear on non-driven wheels. This means that the vibration occurs at varying
Severely incorrect toe settings will also cause vehicle speeds when a different transmission
other unusual wear patterns. gear is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
Tire Vibration Diagnosis the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
A tire vibration diagnostic procedure always
to the tires.
begins with a road test. The road test and
customer interview (if available) will provide much If the road test indicates that there is tire whine,
of the information needed to find the source of a but no shake or vibration, the noise originates
vibration. with the contact between the tire and the road
surface.
During the road test, drive the vehicle on a road
that is smooth and free of undulations. If vibration A thumping noise usually means that the tire is
is apparent, note and record the following: flat or has soft spots making a noise as they slap
the roadway. Tire whine can be distinguished
– the speed at which the vibration occurs.
from axle noise. Tire whine remains the same
– what type of vibration occurs in each speed over a range of speeds.
range.
A complete road test procedure is described in
- mechanical or audible
Section 100-04. REFER to Section 100-04.
– how the vibration is affected by changes in
the following:

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204-04-4 Wheels and Tires 204-04-4

DIAGNOSIS AND TESTING

Symptom Chart

Condition Possible Sources Action

• Tires show excess wear on • Tires under-inflated. • ADJUST the tire pressure.
edge of tread
• Vehicle overloaded. • CORRECT as necessary.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Tires show excess wear in cen- • Tires over-inflated. • ADJUST the tire pressure.
ter of tread
• Other excessive tire wear con- • Incorrect tire pressure. • ADJUST the tire pressure.
cerns
• Tires need rotating. • ROTATE the tires.
• Incorrect wheel alignment. • ADJUST the wheel alignment.
• Vehicle overloaded. • CORRECT as necessary.
• Loose or leaking front strut and • TIGHTEN or INSTALL new sus-
spring assembly. pension components as neces-
sary. REFER to Section 204-01.
• Wheel bearings worn. • INSTALL new wheel bearings
as necessary. REFER to Sec-
tion 204-01 / 204-02.
• Suspension components, bush- • CHECK or INSTALL new sus-
ings and ball joints. pension components as neces-
sary.
• Excessive lateral or radial • CHECK the wheel and tire radial
runout of wheel or tire. runout. REFER to Section 204-
00.
• Wheel mounting is difficult • Incorrect application or mis- • FOLLOW manufacturers speci-
matched parts, including wheel fications.
studs and nuts.
• Wheel rust or corrosion • Poor maintenance. • CLEAN and PROTECT with
paint.
• Wobble or shimmy affecting • Damaged wheel. • INSPECT wheel rims for dam-
wheel runout age. INSTALL new parts as
necessary.
• Front wheel bearing. • CHECK or INSTALL new wheel
bearings as necessary.
REFER to Section 204-01.
• Excessive vehicle vibration, • Suspension components. • CHECK or INSTALL new parts.
rough steering REFER to Section 204-00.
• Vehicle vibrations from wheels • Incorrect tire pressure. • ADJUST the tire pressure.
and tires
• Wheel or tire imbalance. • BALANCE the tire and wheel
assembly.

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204-04-5 Wheels and Tires 204-04-5

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Uneven tire wear. • INSTALL a new tire(s) as nec-
essary.
• Brake disc imbalance. • CHECK the brake disc for for-
eign material.
• Water in tires. • REMOVE the water.
• Bent wheel. • INSTALL a new wheel. Attempts
to straighten a wheel can cause
fractures in the wheel and
weaken the wheels strength.
• Incorrectly seated tire bead. • SPIN the wheel on the vehicle.
EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
• Radial runout of wheel or tire. • Using a suitable dial indicator
gauge and holding fixture,
CHECK the radial runout of both
the wheel and the tire.
REFER to Section 204-00.
• Wheel stud, wheel nut or • CHECK or INSTALL new parts
enlarged stud holes. as necessary.
• Foreign material between wheel • CLEAN mounting surfaces.
mounting face and hub mount-
ing surface.
• Lateral runout of wheel or tire. • Using a suitable dial indicator
gauge and holding fixture,
CHECK the radial runout of both
the wheel and the tire.
REFER to Section 204-00.
• Front wheel bearing. • CHECK or INSTALL a new
wheel bearing as necessary.
REFER to Section 204-01.
• Cracks develop in rim base back • Overloading or abusive use. • INSTALL a new wheel. CHECK
(rim bead seat) loading and operating condi-
tions. AVOID over inflation of
tires. CHECK the specifications
for the rim load capacity, work-
ing load, tire size, ply rating and
tire construction.
• Incorrect use of tools. • CHECK mounting, demounting,
and maintenance procedures.

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204-04-6 Wheels and Tires 204-04-6

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Damaged wheel studs • Sliding wheel across wheel • INSTALL new wheel studs as
studs during assembly. necessary. INSTALL a new
wheel as necessary.
• Loose brake drum • Wheel studs too long. • INSTALL new wheel studs of
the correct length as necessary.
• Broken wheel studs • Loose wheel nuts. • INSTALL new wheel studs and
nuts. TIGHTEN to specification.
• Overloading. • INSTALL new wheel studs.
TIGHTEN to specification.
Compare actual load against
vehicle load ratings.
• Stripped wheel stud threads • Excessive tightening. • INSTALL new wheel studs and
nuts. TIGHTEN to specification.
• Rust streaks from the wheel • Wheel nuts. • CHECK complete assembly. If
stud holes in the wheel parts are damaged INSTALL
new parts. TIGHTEN to specifi-
cation.
• Damaged wheel nuts • Wheel assembly. • INSTALL new wheel nuts.
TIGHTEN to specification.
• Over tightened wheel nuts. • FOLLOW correct tightening pro-
cedure.
• Seized wheel nuts • Corrosion. • CAUTION: Do not permit lubri-
cant to get on cone sets of stud
holes or on cone angle of wheel
nuts. If corrosion is slight, wire
brush away. If corrosion is ex-
cessive, INSTALL new wheel
studs and nuts. If the condition
persists, LUBRICATE the first
three threads of each wheel
stud with a graphite-based lubri-
cant.
• Overloading • REDUCE weight.

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204-04-7 Wheels and Tires 204-04-7

REMOVAL AND INSTALLATION

Wheel and Tire

REMOVAL AND INSTALLATION

Removal
CAUTION: Do not use heat to loosen a
seized wheel nut. Heat may damage the
wheel and wheel hub.
1. Loosen the wheel nuts.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
3. Remove the wheel and tire.

Installation
1. WARNING: Remove any corrosion or
dirt from the mounting surfaces of the
wheel, wheel hub or brake disc.
Corrosion or dirt on the mounting
surfaces may cause the wheel nuts to
loosen and the wheel to come off
while the vehicle is in motion. Failure
to follow this instruction may result in
personal injury.
Clean the wheel hub and mounting
surfaces.
2. Install the wheel and tire.
3. Lower the vehicle.
4. Tighten the wheel nuts in the sequence
shown.

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205-04-1 Front Drive Halfshafts 205-04-1

SECTION 205-04 Front Drive Halfshafts

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 205-04-2

DESCRIPTION AND OPERATION

Front Drive Halfshafts........................................................................................................ 205-04-3

Working principle of the halfshafts .................................................................................... 205-04-9
Handling halfshafts........................................................................................................... 205-04-9
Wheel balancing, front...................................................................................................... 205-04-9
Raising the vehicle ........................................................................................................... 205-04-9
Towing the vehicle............................................................................................................ 205-04-9
Underbody protection and corrosion prevention ............................................................... 205-04-9

DIAGNOSIS AND TESTING

Front Drive Halfshafts........................................................................................................ 205-04-11

Inspection and Verification ............................................................................................... 205-04-11
Symptom Chart – Front Drive Halfshafts .......................................................................... 205-04-11

REMOVAL AND INSTALLATION

Halfshaft LH.................................................................................................. (14 320 0) 205-04-12

Halfshaft RH ................................................................................................. (14 321 0) 205-04-23
Intermediate Shaft ............................................................................................................. 205-04-34
Constant Velocity (CV) Joint Boot...................................................................................... 205-04-38

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205-04-2 Front Drive Halfshafts 205-04-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Grease, outer constant velocity (CV) joint XS4C-M1C230-AA
Grease, inner CV joint WSD-M1C230-A

Constant Velocity (CV) Joint Boot Capacities

Description
Grease, outer CV joint 55
Grease, inner CV joint (vehicles with 1.8L or 2.0L engine) 155
Grease, inner CV joint (vehicles with 2.5L engine) 165
Grease, inner CV joint (vehicles with 2.0L diesel engine) 165

Torque Specifications
Description Nm lb-ft lb-in
Intermediate shaft center bearing retaining nuts 25 18 –
Intermediate shaft center bearing to cylinder block 48 35 –
bracket retaining bolts (vehicles with 1.8L or 2.0L
engine)
Stabilizer bar connecting link to suspension strut 48 35 –
retaining nut
Suspension top mount thrust bearing retaining nut 59 44 –
Hub retaining nut 290 214 –
Boot clamps 21 15 –
Engine undershield retaining bolts 10 – 89
Subframe retaining bolts 142 – 105
Subframe bracket retaining bolts 10 – 89
Lower arm to wheel knuckle pinch nut and bolt 83 61 –

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205-04-3 Front Drive Halfshafts 205-04-3

DESCRIPTION AND OPERATION

Front Drive Halfshafts

DESCRIPTION AND OPERATION

– The halfshafts have constant velocity (CV)

joints at both ends to provide smooth drive to
the road wheels.
– The inner CV joints are sliding joints.
– The outer CV joints are fixed ball joints.
– The left-hand halfshaft CV joint is secured in
the differential with a snap ring.
– The intermediate shaft (right-hand side) is
secured in the differential by the intermediate
shaft center bearing.
– The right-hand halfshaft is secured on the
intermediate shaft with a snap ring.
– The outer CV joints are attached to the wheel
hubs.

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205-04-4 Front Drive Halfshafts 205-04-4

DESCRIPTION AND OPERATION

Exploded view of the halfshaft (vehicles with 2.5L engine)

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205-04-5 Front Drive Halfshafts 205-04-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
1 - Solid halfshaft with fixed 7 - Inner CV joint housing
outer CV joint
8 - Snap ring - stub shaft
2 - Boot retaining clamp (large)
9 - Solid intermediate shaft with
3 - CV joint boot intermediate shaft center
bearing
4 - Boot retaining clamp (small)
10 - Snap ring - intermediate
5 - Circlip - spider
shaft
6 - Inner CV joint bearing

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205-04-6 Front Drive Halfshafts 205-04-6

DESCRIPTION AND OPERATION

Exploded view of the halfshaft (vehicles with 2.0L diesel engine)

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205-04-7 Front Drive Halfshafts 205-04-7

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
1 - Solid halfshaft with fixed 7 - Inner CV joint housing
outer CV joint
8 - Snap ring - stub shaft
2 - Boot retaining clamp (large)
9 - Solid intermediate shaft with
3 - CV joint boot intermediate shaft center
bearing
4 - Boot retaining clamp (small)
10 - Snap ring - intermediate
5 - Circlip - spider
shaft
6 - Inner CV joint bearing
11 - Dynamic absorber

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205-04-8 Front Drive Halfshafts 205-04-8

DESCRIPTION AND OPERATION

Exploded view of the halfshaft (vehicles with 1.8 or 2.0L engine)

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205-04-9 Front Drive Halfshafts 205-04-9

DESCRIPTION AND OPERATION (Continued)

Item Part Description – Check polished surfaces and splines for

Number damage.
– Do not allow the boots to come into contact
1 - Tubular halfshaft with fixed with sharp edges, the engine or the exhaust
outer CV joint system.
2 - Boot retaining clamp (large) – Do not drop the halfshaft as this can damage
3 - CV joint boot the inside of the CV joint boots without
showing any signs of damage on the outside.
4 - Boot retaining clamp (small) – Do not use halfshafts as levering tools for the
5 - Circlip - spider installation of other components. The
halfshafts must always hang freely.
6 - Inner CV joint bearing
– The tripode joint can be damaged by impact
7 - Inner CV joint housing from outside the joint housing.
8 - Snap ring - stub shaft
9 - Tubular intermediate shaft Wheel balancing, front
with intermediate shaft cen-
ter bearing CAUTION: Using a portable wheel
balancing unit when the vehicle is lifted
10 - Snap ring - intermediate completely off the ground will result in
shaft damage to the tripode joints or boots, as
the joint is bent at a greater angle than
its normal operating range. This results
Working principle of the halfshafts in overheating of the joint.
– The halfshafts transmit torque from the To use a portable balancing unit position a trolley
engine to the wheels. jack under the suspension arm opposite the
wheel which is being balanced. This prevents the
– In order to allow vertical movement of the
joint from being bent too much when the vehicle
wheels and engine, the halfshafts operate at
is raised.
varying lengths and angles.
– The tripode joints allow for changes in Where possible, wheels should be removed for
halfshaft length during axial movements. balancing, and balanced using a stationary wheel
balancing unit.

Handling halfshafts
Raising the vehicle
CAUTION: The inner constant velocity
(CV) joint must not be bent at more than CAUTION: Never use the CV joints or
18 degrees, the outer CV joint must not halfshafts as jacking points.
be bent at more than 45 degrees.
NOTE: Do not place the tripode joint under
tension.
If removing/installing and Towing the vehicle
disassembling/assembling the halfshafts, the NOTE: Do not attach the tow rope to the
following points should be observed: halfshaft.

Underbody protection and corrosion

prevention
NOTE: The boots should be covered during
application of underbody protection or corrosion
prevention.

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205-04-10 Front Drive Halfshafts 205-04-10

DESCRIPTION AND OPERATION (Continued)

Foreign matter on the boots can cause premature
ageing of the material. Foreign matter on the
halfshafts can cause imbalance.

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205-04-11 Front Drive Halfshafts 205-04-11

DIAGNOSIS AND TESTING

Front Drive Halfshafts

DIAGNOSIS AND TESTING

(if possible) before proceeding to the next

step.
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.
3. If an obvious cause for an observed or
reported concern is found, correct the cause
Symptom Chart – Front Drive Halfshafts

Condition Possible Sources Action

• Clicking, Popping or Grinding • Inadequate or contaminated lu- • INSPECT, CLEAN and
Noises While Turning bricant in the inner/outer front LUBRICATE as necessary.
drive halfshaft constant velocity
(CV) joint.
• Another component contacting • INSPECT and REPAIR as
front drive halfshaft assembly. necessary.
• Wheel bearings, brakes, sus- • INSPECT and REPAIR as nec-
pension or steering compo- essary. REFER to Section 204-
nents. 00 / 206-00 / 211-00.
• Vibration at Highway Speeds • Out of balance front wheels or • REPAIR or INSTALL new as
tires. necessary. REFER to Section
• Out-of-round tires. 204-04.
• Incorrectly seated outer con- • REPAIR or INSTALL new as
stant velocity (CV) joint in front necessary. REFER to Section
wheel hub. 204-04.
• REPAIR or INSTALL new as
necessary. REFER to Halfshaft
Disassemblv and Assembly in
this section.
• Shudder Vibration During Ac- • Excessively high CV joint • CHECK ride height, VERIFY
celeration. operating angles caused by correct spring rate and CHECK
incorrect ride height. items under Halfshaft Joint
• Excessively worn or damaged Pullout. REPAIR or INSTALL
inner/outer front drive halfshaft new as necessary.
constant velocity (CV) joint. • INSPECT and INSTALL new as
necessary.
• Halfshaft Joint Pullout • Outer front drive halfshaft • INSPECT and REPAIR or
retainer circlip missing or not INSTALL new as necessary.
correctly seated differential side. • CHECK engine mounts for
• Engine/transaxle assembly damage or wear. REPAIR or
misalignment. INSTALL new as necessary.
• Frame rail or strut tower out of • CHECK underbody dimensions.
position or damaged. • CHECK for worn bushings or
• Front suspension components bent components (front stabi-
worn or damaged. lizer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.

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205-04-12 Front Drive Halfshafts 205-04-12

REMOVAL AND INSTALLATION

Halfshaft LH (14 320 0)

REMOVAL AND INSTALLATION

2. Detach the steering column shaft from the

steering column flexible coupling.
Special Tool(s) 1. Remove the retaining bolt.
2. Rotate the clamp plate.
Installer, Halfshaft
• Discard the bolt.
204-161 (14-041)

Alignment Pins, Subframe

205-316 (15-097A)

Remover, Halfshaft
308-256 (16-089)

3. Remove the suspension strut and spring

assembly top mount brace cover.
General Equipment • Release the clips.

Three leg puller

Transmission jack

Removal
All vehicles
1. CAUTION: Use a socket to loosen the
wheel hub retaining nut to prevent
damage.
Loosen the wheel hub retaining nut.

4. Loosen the strut and spring assembly top

mount retaining nuts by four turns.

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205-04-13 Front Drive Halfshafts 205-04-13

REMOVAL AND INSTALLATION (Continued)

5. Using cable ties, support the radiator on Vehicles with diesel engine
both sides. 8. Remove the engine undershield.

All vehicles
9. Remove the splash shield.

6. Remove the wheel and tire. For additional

information, refer to Section 204-04.
7. CAUTION: The wheel hub retaining nut 10. Remove the radiator support brackets.
can be reused four times, mark the 1. Remove the hose bracket.
retaining nut.
2. Remove both radiator support brackets.
Remove the wheel hub retaining nut.

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REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine Vehicles with 2.5L engine
11. Detach the air intake hose. 15. Remove the exhaust dual converter y-
pipe. For additional information, refer to
Section 309-00.
All vehicles
16. Remove the engine rear support insula-
tor.

12. Detach the turbocharger outlet hose.

All except vehicles with diesel engine

17. Disconnect the catalyst monitor sensor
electrical connector.

All vehicles
13. Detach the stabilizer bar connecting link
from the suspension strut.

18. Detach the catalyst monitor sensor wiring

harness from the subframe.

Vehicles with 1.8L, 2.0L or diesel engine

14. Remove the exhaust flexible pipe. For
additional information, refer to Section
309-00.

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REMOVAL AND INSTALLATION (Continued)

Vehicles with xenon headlamps 22. CAUTION: Do not pull down the lower
19. Detach the headlamp leveling sensor wir- arm, to prevent the lower arm hydro-
ing harness from the subframe. bushing from damage.
Remove the lower arm ball joint retaining
nut and bolt.

All vehicles
20. Detach the radiator cooling fan wiring
harness from the subframe.
23. Remove the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

21. Using two suitable wooden blocks and a

suitable transmission jack, support the
subframe.
24. Remove the subframe front retaining
bolts on both sides.

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REMOVAL AND INSTALLATION (Continued)

25. CAUTION: Lower the subframe 27. CAUTION: Support the halfshaft. The
uniformly, to prevent the lower arm inner joint must not be bent more than
hydro-bushing from damage. 18 degrees. The outer joint must not
be bent more than 45 degrees.
Using the transmission jack, lower the
subframe approximately 150 mm. CAUTION: Do not damage the halfshaft
oil seal.
NOTE: Plug the transaxle to prevent oil loss or
dirt ingress.
Using the special tool, detach the
halfshaft from the transaxle and secure it
to one side.
• Allow the oil to drain into a suitable
container.
• Remove and discard the snap ring.

26. CAUTION: Protect the ball joint seal

using a soft cloth to prevent damage.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

28. Using a suitable three leg puller, detach

the halfshaft from the wheel hub and
remove the halfshaft.

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REMOVAL AND INSTALLATION (Continued)

3. CAUTION: The wheel hub retaining nut

Installation can be reused four times, inspect the
markings on the retaining nut and
All vehicles install a new retaining nut if
necessary.
1. CAUTION: Support the halfshaft. The NOTE: Do not fully tighten the retaining nut at
inner joint must not be bent more than this stage.
18 degrees. The outer joint must not
be bent more than 45 degrees. Install the wheel hub retaining nut.

CAUTION: Do not damage the halfshaft

oil seal.
CAUTION: Make sure the snap ring is
correctly seated.
NOTE: Install a new snap ring.
Attach the left-hand halfshaft to the trans-
axle.

4. CAUTION: Make sure the heat shield is

installed to prevent damage to the ball
joint.
Attach the lower arm to the wheel knuckle
on both sides.
• Install the heat shield.

2. CAUTION: Make sure the halfshaft is

completely installed into the wheel
hub.
Using the special tool, install the halfshaft.

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REMOVAL AND INSTALLATION (Continued)

5. Using the transmission jack, position the 7. CAUTION: While tightening the
subframe. subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

6. Using the special tool and a suitable

washer, align the subframe.
1. Insert the washer with inside diameter 22
mm, outside diameter 44 mm and height 5
mm, into the subframe above the lower
8. CAUTION: While tightening the
alignment hole.
subframe retaining bolts, make sure
2. Insert the alignment pin through the the subframe does not move.
subframe alignment holes and the washer.
Install the subframe front retaining bolts.
3. Slide the locking plates on top of the
washer and into the groove of the tool and • Lower and remove the transmission jack.
tighten the alignment pin sleeve.

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205-04-19 Front Drive Halfshafts 205-04-19

REMOVAL AND INSTALLATION (Continued)

9. Remove the special tools. Vehicles with xenon headlamps

12. Attach the headlamp leveling sensor wir-
ing harness to the subframe.

10. WARNING: Install a new self-locking

nut.
All except vehicles with diesel engine
Install the lower arm joint pinch bolt from 13. Attach the catalyst monitor sensor wiring
the rear, the retaining nut from the front. harness to the subframe.

11. Attach the radiator cooling fan wiring 14. Connect the catalyst monitor sensor elec-
harness to the subframe. trical connector.

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REMOVAL AND INSTALLATION (Continued)

All vehicles Vehicles with diesel engine
15. Install the engine rear support insulator. 19. Attach the turbocharger outlet hose.

Vehicles with 1.8L, 2.0L or diesel engine 20. Attach the air intake hose.
16. Install the exhaust flexible pipe. For
additional information, refer to Section
309-00.
Vehicles with 2.5L engine
17. Install the exhaust dual converter y-pipe.
For additional information, refer to
Section 309-00.
All vehicles
18. Attach the stabilizer bar connecting link
to the suspension strut.

All vehicles
21. Install the radiator support brackets.
1. Install both radiator supports brackets.
2. Install the hose brackets.

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REMOVAL AND INSTALLATION (Continued)

22. Install the splash shield. 26. Remove the cable ties.

Vehicles with diesel engine

23. Install the engine undershield.

27. Tighten the strut and spring assembly

top mount retaining nuts.

All vehicles
24. Install the front wheel and tire. For
additional information, refer to Section
204-04.
25. Tighten the wheel hub retaining nut.

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REMOVAL AND INSTALLATION (Continued)

28. Install the suspension strut and spring
assembly top mount brace cover.

29. WARNING: Install a new steering

column to steering column flexible
coupling retaining bolt. Failure to
follow this instruction may result in
personal injury.
Connect the steering column shaft to the
steering column flexible coupling.
1. Rotate the clamp plate.
2. Install the retaining bolt.

Vehicles with automatic transaxle

30. Refill the transaxle. For additional
information, refer to Section 307-01A /
307-01B.
Vehicles with manual transaxle
31. Check the transmission fluid level and
top up with manual transmission fluid, if
necessary.

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205-04-23 Front Drive Halfshafts 205-04-23

REMOVAL AND INSTALLATION

Halfshaft RH (14 321 0)

Removal
Special Tool(s)
All vehicles
Installer, Halfshaft
204-161 (14-041) 1. CAUTION: Use a socket to loosen the
wheel hub retaining nut to prevent
damage.
Loosen the wheel hub retaining nut.
Remover, Halfshaft
204-226 (16-092)

Adapter for 204-226

204-226-01 (16-092-01)

Slide Hammer
205-047 (15-011) 2. Detach the steering column shaft from the
steering column flexible coupling.
1. Remove the retaining bolt.
2. Rotate the clamp plate.
Alignment Pins, Subframe • Discard the bolt.
205-316 (15-097A)

General Equipment
Three leg puller
Transmission jack

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205-04-24 Front Drive Halfshafts 205-04-24

REMOVAL AND INSTALLATION (Continued)

3. Remove the suspension strut and spring 5. Using cable ties, support the radiator on
assembly top mount brace cover. both sides.
• Release the clips.

4. Loosen the strut and spring assembly top

mount retaining nuts by four turns.

6. Remove the wheel and tire. For additional

information, refer to Section 204-04.
7. CAUTION: The wheel hub retaining nut
can be reused four times, mark the
retaining nut.
Remove the wheel hub retaining nut.

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205-04-25 Front Drive Halfshafts 205-04-25

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine Vehicles with diesel engine

8. Remove the engine undershield. 11. Detach the air intake hose.

All vehicles 12. Detach the turbocharger outlet hose.

9. Remove the splash shield.

All vehicles
10. Remove the radiator support brackets. 13. Detach the stabilizer bar connecting link
1. Remove the hose bracket. from the suspension strut on both sides.
2. Remove both radiator support brackets.

Vehicles with 1.8L, 2.0L or diesel engine

14. Remove the exhaust flexible pipe. For
additional information, refer to Section
309-00.

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205-04-26 Front Drive Halfshafts 205-04-26

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.5L engine Vehicles with xenon headlamps
15. Remove the exhaust dual converter y- 19. Detach the headlamp leveling sensor wir-
pipe. For additional information, refer to ing harness from the subframe.
Section 309-00.
All vehicles
16. Remove the engine rear support insula-
tor.

All vehicles
20. Detach the radiator cooling fan wiring
harness from the subframe.

All except vehicles with diesel engine

17. Disconnect the catalyst monitor sensor
electrical connector.

21. Using two suitable wooden blocks and a

suitable transmission jack, support the
subframe.

18. Detach the catalyst monitor sensor wiring

harness from the subframe.

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205-04-27 Front Drive Halfshafts 205-04-27

REMOVAL AND INSTALLATION (Continued)

22. CAUTION: Do not pull down the lower 25. CAUTION: Lower the subframe
arm, to prevent the lower arm hydro- uniformly, to prevent the lower arm
bushing from damage. hydro-bushing from damage.
Remove the lower arm ball joint retaining Using the transmission jack, lower the
nut and bolt. subframe approximately 150 mm.

23. Remove the subframe rear retaining bolts 26. CAUTION: Protect the ball joint seal
and the subframe bracket retaining bolts using a soft cloth to prevent damage.
on both sides.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

24. Remove the subframe front retaining

bolts on both sides.

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REMOVAL AND INSTALLATION (Continued)

Installation
27. CAUTION: Support the halfshaft. The All vehicles
inner joint must not be bent more than
18 degrees. The outer joint must not 1. CAUTION: Support the halfshaft. The
be bent more than 45 degrees. inner joint must not be bent more than
18 degrees. The outer joint must not
Using the special tools, detach the
be bent more than 45 degrees.
halfshaft from the intermediate shaft and
secure it to one side (vehicles with 2.5L CAUTION: Make sure the snap ring is
engine shown). correctly seated.
• Remove and discard the snap ring. NOTE: Install a new snap ring.
Attach the halfshaft to the intermediate
shaft (vehicles with 2.5L engine shown).

28. Using a suitable three leg puller, detach

the halfshaft from the wheel hub and
remove the halfshaft.
2. CAUTION: Make sure the wheel hub is
completely installed into the wheel
hub.
Using the special tool, install the halfshaft.

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205-04-29 Front Drive Halfshafts 205-04-29

REMOVAL AND INSTALLATION (Continued)

3. CAUTION: The wheel hub retaining nut 5. Using the transmission jack, position the
can be reused four times, inspect the subframe.
markings on the retaining nut and
install a new retaining nut if
necessary.
NOTE: Do not fully tighten the retaining nut at
this stage.
Install the retaining nut.

6. Using the special tools and a suitable

washer, align the subframe.
1. Insert the washer, with inside diameter 22
mm, outside diameter 44 mm and height 5
mm, into the subframe above the lower
alignment hole.
2. Insert the alignment pin through the
4. CAUTION: Make sure the heat shield is
subframe alignment holes and the washer.
installed to prevent damage to the ball
joint. 3. Slide the locking plates on top of the
washer and into the groove of the tool and
Attach the lower arm to the wheel knuckle tighten the alignment pin sleeve.
on both sides.
• Install the heat shield.

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205-04-30 Front Drive Halfshafts 205-04-30

REMOVAL AND INSTALLATION (Continued)

7. CAUTION: While tightening the 9. Remove the special tools.

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

10. WARNING: Install a new self-locking

nut.
Install the lower arm ball joint pinch bolt
from the rear, the retaining nut from the
front.
8. CAUTION: While tightening the
subframe retaining bolts, make sure
the subframe does not move.
Install the subframe front retaining bolts.
• Lower and remove the transmission jack.

11. Attach the radiator cooling fan wiring

harness to the subframe.

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205-04-31 Front Drive Halfshafts 205-04-31

REMOVAL AND INSTALLATION (Continued)

Vehicles with xenon headlamps All vehicles

12. Attach the headlamp leveling sensor wir- 15. Install the engine rear support insulator.
ing harness to the subframe.

Vehicles with 1.8L, 2.0L or diesel engine

All except vehicles with diesel engine 16. Install the exhaust flexible pipe. For
13. Attach the catalyst monitor sensor wiring additional information, refer to Section
harness to the subframe. 309-00.
Vehicles with 2.5L engine
17. Install the exhaust dual converter y-pipe.
For additional information, refer to
Section 309-00.
All vehicles
18. Attach the stabilizer bar connecting link
to the suspension strut on both sides.

14. Connect the catalyst monitor sensor elec-

trical connector.

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205-04-32 Front Drive Halfshafts 205-04-32

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine 22. Install the splash shield.
19. Attach the turbocharger outlet hose.

Vehicles with diesel engine

20. Attach the air intake hose. 23. Install the engine undershield.

All vehicles All vehicles

21. Install the radiator support brackets. 24. Install the wheel and tire. For additional
1. Install both radiator support brackets. information, refer to Section 204-04.
2. Install the hose bracket. 25. Tighten the wheel hub retaining nut.

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205-04-33 Front Drive Halfshafts 205-04-33

REMOVAL AND INSTALLATION (Continued)

26. Remove the cable ties. 28. Install the suspension strut and spring
assembly top mount brace cover.

29. WARNING: Install a new steering

column to steering column flexible
coupling retaining bolt. Failure to
follow this instruction may result in
personal injury.
Connect the steering column shaft to the
steering column flexible coupling.
1. Rotate the clamp plate.
2. Install the retaining bolt.

27. Tighten the strut and spring assembly

top mount retaining nuts.

Vehicles with automatic transaxle

30. Refill the transaxle. For additional
information, refer to Section 307-01A /
307-01B.
Vehicles with manual transaxle
31. Check the transmission fluid level and
top up with manual transmission fluid, if
necessary.

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205-04-34 Front Drive Halfshafts 205-04-34

REMOVAL AND INSTALLATION

Intermediate Shaft
2. CAUTION: Use an Allen key to prevent
the piston rod from rotating.
Special Tool(s) Loosen the right-hand top mount nut by
Remover, Halfshaft five turns.
204-226 (16-092)

Adapter for 204-226

204-226-01 (16-092-01)

Slide hammer
205-047 (15-011)
3. Detach the right-hand stabiliser connect-
ing link from the suspension strut.

Removal
All vehicles
1. Remove the right-hand suspension strut
and spring assembly top mount brace
cover.
• Release the clips.

4. Remove the right-hand wheel and tire. For

additional information, refer to Section
204-04.
5. NOTE: The lower arm remains installed.
Detach the right-hand lower arm ball joint
from the wheel knuckle. For additional
information, refer to Section 204-01.

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205-04-35 Front Drive Halfshafts 205-04-35

REMOVAL AND INSTALLATION (Continued)

6. CAUTION: Support the halfshaft. The Vehicles with 2.0L diesel engine
inner joint must not be bent more than
8. CAUTION: Do not damage the halfshaft
18 degrees. The outer joint must not
oil seal.
be bent at more than 45 degrees.
NOTE: Plug the transaxle to prevent oil loss or
Using the special tools, detach the right- dirt ingress.
hand halfshaft from the intermediate shaft
and secure it to one side (vehicles with Remove the intermediate shaft.
2.5L engine shown). • Remove and discard the center bearing
• Remove and discard the snap ring. cap and locknuts.
• Allow the oil to drain into a suitable con-
tainer.

Vehicles with 2.5L engine

7. CAUTION: Do not damage the halfshaft Vehicles with 1.8L or 2.0L engine
oil seal.
NOTE: Plug the transaxle to prevent oil loss and 9. CAUTION: Do not damage the halfshaft
dirt ingress. oil seal.
NOTE: Plug the transaxle to prevent oil loss or
Remove the intermediate shaft.
dirt ingress.
• Remove and discard the center bearing
locknuts. Remove the intermediate shaft.
• Allow the oil to drain into a suitable con- • Remove and discard the center bearing
tainer. cap and locknuts.
• Allow the oil to drain into a suitable con-
tainer.

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205-04-36 Front Drive Halfshafts 205-04-36

REMOVAL AND INSTALLATION (Continued)

Installation Vehicles with 2.5L engine

All Vehicles 3. CAUTION: Do not damage the halfshaft

oil seal.
1. CAUTION: Do not damage the halfshaft NOTE: Install new halfshaft center bearing
oil seal. locknuts.
NOTE: Install a new halfshaft center bearing cap
Install the intermediate shaft.
and locknuts.
• Install the locknuts.
Install the intermediate shaft.
• Install the center bearing cap.

All vehicles

Vehicles with 2.0L diesel engine 4. CAUTION: Support the halfshaft. The
inner joint must not be bent more than
2. CAUTION: Do not damage the damage 18 degrees. The outer joint must not
the halfshaft oil seal. be bent at more than 45 degrees.
NOTE: Install a new halfshaft center bearing cap
CAUTION: Make sure the snap ring is
and locknuts.
correctly seated.
Install the intermediate shaft. NOTE: Install a new snap ring.
• Install the center bearing cap.
Attach the right-hand halfshaft to the in-
termediate shaft (vehicles with 2.5L engine
shown).

5. Attach the right-hand lower arm ball joint

to the wheel knuckle. For additional
information, refer to Section 204-01.

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205-04-37 Front Drive Halfshafts 205-04-37

REMOVAL AND INSTALLATION (Continued)

6. Attach the right-hand stabiliser connecting 10. Check the transaxle fluid level and top up
link to the suspension strut. with manual transmission fluid if
necessary.

7. Install the right-hand wheel and tire. For

additional information, refer to Section
204-04.
8. CAUTION: Use an Allen key to prevent
the piston rod from rotating.
Tighten the right-hand top mount nut.

9. Install the right-hand suspension strut and

spring assembly top mount brace cover.

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205-04-38 Front Drive Halfshafts 205-04-38

REMOVAL AND INSTALLATION

Constant Velocity (CV) Joint Boot

2. CAUTION: The inner constant velocity
(CV) joint must not be bent more than
Special Tool(s) 18 degrees. The outer CV joint must
not be bent more than 45 degrees.
Clamping Tool, Boot
Retaining Clamp CAUTION: The outer CV joint is a press
204-169 (14-044) fit. Do not disassemble.
CAUTION: Use vise jaw protectors.
Clamp the halfshaft in a vise.
Remover/Installer, Vibration 3. Detach the inner CV joint housing from the
Damper Halfshaft halfshaft.
204-346 (14-068) 1. Remove and discard the inner CV joint
boot retaining clamps.
2. Remove the inner CV joint housing and
Installer, Drive Pinion discard the grease filling.
Bearing
205-068 (15-042)

Remover, Bearing/Gear
205-310 (15-091)

Remover, Bearing/Gear
205-311 (15-092)

4. Remove the spider circlip.

Installer, Transmission
Extension Housing
Bushing/Seal
308-046 (16-016)

Name Specification
Grease XS4C-M1C230-AA
Grease WSD-M1C230-A

Removal
All Vehicles
1. Remove the halfshaft. For additional
information, refer to Halfshaft LH /
Halfshaft RH in this section.

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REMOVAL AND INSTALLATION (Continued)

5. Using the special tools, remove the CV 7. Using the special tools, remove the dy-
joint spider. namic absorber.
• Discard the inner CV joint boot.

Vehicles with 2.0L diesel engine

6. Clean the halfshaft mating faces.

8. NOTE: Mark the halfshaft where the outer CV

joint boot is located.
Remove and discard the outer CV joint
boot retaining clamps.

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REMOVAL AND INSTALLATION (Continued)

9. Remove the outer CV joint boot. Vehicles with 2.0L diesel engine
• Pull the boot inwards over the halfshaft.
3. CAUTION: Make sure that the amount
of grease in the CV joint does not
exceed 120 grams.
Apply grease to the outer CV joint.
4. NOTE: Install a new outer CV joint boot.
NOTE: Make sure that the outer CV joint boot is
installed at the marks on the halfshaft.
Install the outer CV joint boot.
• Use a suitable screwdriver under the boot
to allow air to escape.

All vehicles except 2.0L diesel engine

10. CAUTION: The outer CV joint is a
press fit. Do not disassemble.
Remove the outer CV joint boot.
• Discard the outer CV joint boot and retain-
ing clamps.

5. NOTE: Measure the length of the absorber

(e.g. 70 mm) and add X = 125±1 mm to the
resulting measurement.
Mark the installation position of the
dynamic absorber.
• Example: 70 mm + 125±1 mm = 195±1
mm

Installation
All Vehicles
CAUTION: The inner CV joint must not be
bent more than 18 degrees. The outer CV
joint must not be bent more than 45
degrees.
1. CAUTION: Use vise jaw protectors.
Clamp the halfshaft in a vise.
2. Pack the outer CV joint with grease.

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205-04-41 Front Drive Halfshafts 205-04-41

REMOVAL AND INSTALLATION (Continued)

All vehicles except 2.0L diesel engine

6. CAUTION: Do not exceed a pressing
force more than 10 kN. Failure to 9. NOTE: Install a new outer CV joint boot.
follow this instruction may result in NOTE: Make sure that the outer CV joint boot is
damage to the outer CV joint. installed at the marks on the halfshaft.
CAUTION: Make sure that the dynamic Install the outer CV joint boot.
absorber and the halfshaft mating faces • Use a suitable screwdriver under the boot
are free of oil and grease. to allow air to escape.
Using the special tool and a suitable tube,
install the dynamic absorber to the marked
position.

All vehicles
10. NOTE: Install a new outer CV joint boot
retaining clamp.
Using the special tool, install the CV joint
boot inner retaining clamp.

Vehicles with 1.8L or 2.0L engine

7. CAUTION: Make sure that the amount
of grease in the CV joint does not
exceed 100 grams.
Apply grease to the outer CV joint.
Vehicles with 2.5L engine
8. CAUTION: Make sure that the amount
of grease in the CV joint does not
exceed 115 grams.
Apply grease to the outer CV joint.

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205-04-42 Front Drive Halfshafts 205-04-42

REMOVAL AND INSTALLATION (Continued)

11. NOTE: Install a new outer CV joint boot 12. NOTE: Install a new inner CV joint boot.
retaining clamp.
Install the inner CV joint boot.
Using the special tool, install the CV joint
boot outer retaining clamp.

13. NOTE: To obtain the correct inner CV joint

boot installation position, make sure that the
distance between the inner and outer CV joint
boot is as indicated.
Align the inner CV joint boot.
• X = 180 mm (halfshafts, vehicles with 1.8L
or 2.0L engine).
• X = 160 mm (left-hand halfshaft, vehicles
with 2.0L engine and automatic transaxle).
• X = 165.5 mm (halfshafts, vehicles with
2.5L or diesel engine).

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205-04-43 Front Drive Halfshafts 205-04-43

REMOVAL AND INSTALLATION

14. NOTE: Install a new inner CV joint boot Vehicles with 1.8L or 2.0L engine
retaining clamp.
17. CAUTION: Make sure that the amount
Using the special tool, install the CV joint of grease in the CV joint does not
boot inner retaining clamp. exceed 155 grams.
Apply grease to the inner CV joint.
Vehicles with 2.5L engine
18. CAUTION: Make sure that the amount
of grease in the CV joint does not
exceed 165 grams.
Apply grease to the inner CV joint.
Vehicles with 2.0L diesel engine
19. CAUTION: Make sure that the amount
of grease in the CV joint does not
exceed 165 grams.
Apply grease to the inner CV joint.
All vehicles
15. CAUTION: Make sure that the CV joint
20. Attach the inner CV joint housing to the
bearings are not damaged.
halfshaft.
Using the special tool, install the CV joint 1. Use a suitable screwdriver under the CV
spider. joint boot to allow air to escape.
2. Install the CV joint housing and pull it
backwards 20 mm.

16. Install the spider circlip.

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205-04-44 Front Drive Halfshafts 205-04-44

REMOVAL AND INSTALLATION (Continued)

21. NOTE: Install a new inner CV joint boot
retaining clamp.
NOTE: Do not move the inner CV joint housing.
Make sure that the CV joint boot is clamped at
the measured position.
Using the special tool, install the CV joint
boot outer retaining clamp.

22. Install the halfshaft. For additional

information, refer to Halfshaft LH /
Halfshaft RH in this section.

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206-00-1 Brake System - General Information 206-00-1

SECTION 206-00 Brake System - General Information

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Brake System .................................................................................................................... 206-00-2

DIAGNOSIS AND TESTING

Brake System .................................................................................................................... 206-00-3

Principles of Operation ..................................................................................................... 206-00-3
Inspection and Verification ............................................................................................... 206-00-3
Road Test......................................................................................................................... 206-00-3
Symptom Chart ................................................................................................................ 206-00-4
Pinpoint Tests .................................................................................................................. 206-00-6
Component Tests ............................................................................................................. 206-00-9
Emergency Brake Assist (EBA) ......................................................................................... 206-00-11
Principles of Operation ..................................................................................................... 206-00-11
Inspection and Verification ............................................................................................... 206-00-11
Function Tests.................................................................................................................. 206-00-11

GENERAL PROCEDURES

Brake System Bleeding ................................................................................ (12 141 0) 206-00-13

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206-00-2 Brake System - General Information 206-00-2

DESCRIPTION AND OPERATION

Brake System
DESCRIPTION AND OPERATION

NOTE: Brake friction materials inherently capability with a reduced brake pedal effort
generate noise and heat in order to dissipate during critical situations.
energy. As a result, occasional squeal is
possible. This condition may be amplified by
severe operating conditions, such as cold, heat,
rain, snow, salt and mud.
The braking system is of a diagonally split, dual
circuit design featuring front and rear disc brakes.
Vehicles with steel wheels are equipped with
standard brake discs and vehicles with alloy
wheels are equipped with anti-corrosion coated
brake discs.
The hydraulic system has separate circuits for
each pair of diagonally opposed wheels (left
front, right rear and right front, left rear). The front
brake caliper is of a single sliding piston design
which makes sure that equal effort is applied
through both brake pads.
The anti-lock brake system (ABS) is controlled by
the hydraulic control unit (HCU), incorporated
within the hydraulic system, and only operates
when the wheel speed sensors detect the onset
of wheel lock up.
The parking brake control operates the rear
brakes through a cable system. The parking
brake cable features automatic adjustment using
a ratchet and pawl mechanism on the parking
brake control assembly.
The brake master cylinder is of a tandem design
and is linked to a brake booster which reduces
the brake pedal effort. The tandem design will
make sure that in the event of one brake circuit
failing the other will remain fully operational.
The brake master cylinder and brake booster are
located on the left-hand side of the engine
compartment. On right-hand drive vehicles they
are connected to the brake pedal via a brake
pedal cross shaft. On left-hand drive vehicles the
brake booster actuating rod is connected directly
to the brake pedal.
The brake booster vacuum on vehicles with
diesel engine is provide by a camshaft driven
vacuum pump.
The emergency brake assist (EBA) system
incorporates a hydraulic mechanism in the brake
master cylinder allowing controlled additional
assistance to brake pedal effort in emergency
braking situations. This allows maximum braking

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206-00-3 Brake System - General Information 206-00-3

DIAGNOSIS AND TESTING

Brake System
DIAGNOSIS AND TESTING

An experienced brake technician will always

establish a route that will be used for all brake
Principles of Operation diagnosis road tests. The roads selected will be
The brake system operates by transferring effort reasonably smooth and level. Gravel or bumpy
applied to the brake pedal by the driver to the roads are not suitable because the surface does
brakes at each wheel. not allow the tires to grip the road equally.
Crowned roads should be avoided because of
The braking effort is distributed to each wheel,
the large amount of weight shifted to the low set
using an hydraulic system. The system is
of wheels on this type of road. Once the route is
assisted using a vacuum brake booster that
established and consistently used, the road
reduces pedal effort and increases hydraulic
surface variable can be eliminated from the test
pressure. The parking brake operates on the rear
results.
wheels and is applied using a hand operated
control. Before a road test, obtain a complete description
of the customer concerns or suspected condition.
From the description, the technician's experience
Inspection and Verification will allow the technician to match possible causes
with symptoms. Certain components will be
1. Verify the customer concern. tagged as possible suspects while other will be
2. Visually inspect for obvious signs of eliminated by the evidence. More importantly, the
mechanical damage. customer description can reveal unsafe
conditions which should be checked or corrected
Visual Inspection Chart before the road test. The description will also
Mechanical help form the basic approach to the road test by
narrowing the concern to specific components,
• Tire pressure
vehicle speed or conditions.
• Wheels and tires
Begin the road test with a general brake
• Fluid leak from brake line(s)
performance check. Keeping the description of
• Fluid level the concern in mind, test the brakes at different
• Fluid contamination vehicle speeds using both light and heavy pedal
3. If an obvious cause for an observed or pressure. To determine if the concern is in the
reported concern is found, correct the cause front or rear braking system, use the brake pedal
(if possible) before proceeding to the next and then use the parking brake control. If the
step. condition (pull, vibration, isolation) occurs only
with the parking brake, the concern is in the rear
4. If the concern is not visually evident, verify
brake system.
the symptom and refer to the Symptom
Chart. Avoid locking the brakes and sliding the tires.
Locked brakes and sliding tires do not indicate
brake efficiency. A heavily braked and turning
Road Test wheel will stop the vehicle in a shorter distance
than locked brakes.
Carry out a road test to compare actual vehicle
braking performance with the performance If the concern becomes evident during this check,
standards expected by the driver. The ability of verify it fits the description given before the road
the test driver to make valid comparison and test. If the concern is not evident, attempt to
detect performance deficiencies will depend on duplicate the condition using the information from
experience. the description.
The driver should have a thorough knowledge of If a concern exists, use the Symptom Chart in
brake system operation and accepted general order to isolate it to a specific sub-system and
performance guidelines to make good condition description. From this description, a list
comparisons and detect performance concerns. of possible sources can be used to further narrow
the cause to a specific component or condition.

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206-00-4 Brake System - General Information 206-00-4

DIAGNOSIS AND TESTING

Symptom Chart

Condition Possible Sources Action

• The brakes pull or drift • Wheel alignment angles. • CHECK the wheel alignment
angles. REFER to Section 204-
00.
• Brake pads. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake disc. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake caliper. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• The red brake warning indicator • Brake fluid level sensor. • REFER to WDS.
is always on
• Parking brake control. • RELEASE and ADJUST the
parking brake. REFER to Sec-
tion 206-05.
• Excessively worn brake pads. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake master cylinder primary • INSTALL a new brake master
piston cup. cylinder. REFER to Section 206-
06.
• Vibration when brakes are ap- • Brake pads. • CHECK and INSTALL new
plied components as necessary.
REFER to Section 206-03 /
206-04.
• Brake caliper. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake disc. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 /
206-04.
• The pedal goes down fast • Air in system. • BLEED the system. REFER to
Section 206-00.
• Brake master cylinder • Carry out the brake master cyl-
inder component test in this sec-
tion.

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206-00-5 Brake System - General Information 206-00-5

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Brake disc. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake pads. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• The pedal eases down slowly • Brake caliper • CHECK and INSTALL new
components as necessary.
CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 /
206-04.
• Brake master cylinder. • Carry out the brake master cyl-
inder component test in this sec-
tion.
• The pedal is low or feels spongy • Air in system. • Bleed the system. REFER to
Section 206-00.
• Brake pads. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 /
206-04.
• Brake booster • CARRY out the brake booster
component test in this section.
• Brake lockup during light brake • Brake pads. • CHECK and INSTALL new
pedal force components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake disc. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake booster. • CARRY out the brake booster
component test in this section.
• Excessive/erratic brake pedal • Insufficient grease on sliding • APPLY grease where neces-
travel parts. sary.
• Brake pads. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.
• Brake disc. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 / 206-
04.

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206-00-6 Brake System - General Information 206-00-6

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Wheel bearing. • CHECK or INSTALL a new
wheel bearing. REFER to Sec-
tion 204-01.
• Brake pedal. • GO to Pinpoint Test A
• Brake drag • Brake booster. • Carry out the brake booster
component test in this section.
• Brake caliper. • CHECK and INSTALL new
components as necessary.
REFER to Section 206-03 /
206-04.
• Stability assist system (if • REFER to WDS.
equipped)
• Brake pedal. • GO to Pinpoint Test B
• Slow or incomplete brake pedal • Stability assist system (if • REFER to WDS.
return equipped)
• Brake master cylinder. • Carry out the brake master cyl-
inder component test in this sec-
tion.
• Brake pedal. • GO to Pinpoint Test C

Pinpoint Tests
PINPOINT TEST A: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at fast idle whilst making sev-
eral brake applications.
2 Pull the brake pedal upwards.
3 Release the brake pedal and measure the dis-
tance from the rubber to the floor.
4 Make a hard brake application.
5 Release the brake pedal and measure the dis-
tance from brake pedal rubber to the floor. The
brake pedal should return to its original posi-
tion.
• Does the brake pedal return to its original posi-
tion?
→ Yes
Vehicle is OK.
→ No
GO to A2
A2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal to make sure it is oper-
ating freely.
• Is the brake pedal operating freely?

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206-00-7 Brake System - General Information 206-00-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
INSTALL a new brake booster. REFER to
Section 206-07. TEST the system for nor-
mal operation.
→ No
REPAIR or INSTALL new brake pedal and
bracket. TEST the system for normal opera-
tion.
PINPOINT TEST B: BRAKES DRAG
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at fast idle whilst making sev-
eral brake applications
2 Pull the brake pedal upwards.
3 Release the brake pedal and measure the dis-
tance from the rubber to the floor.
4 Make a hard brake application.
5 Release the brake pedal and measure the dis-
tance from brake pedal rubber to the floor. The
brake pedal should return to its original posi-
tion.
• Does the brake pedal return to its original posi-
tion?
→ Yes
Vehicle is OK.
→ No
GO to B2
B2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal to make sure it is oper-
ating freely.
• Is the brake pedal operating freely?
→ Yes
INSTALL a new brake booster. REFER to
Section 206-07. TEST the system for nor-
mal operation.
→ No
REPAIR or INSTALL new brake pedal and
bracket. TEST the system for normal opera-
tion.
PINPOINT TEST C: SLOW OR INCOMPLETE BRAKE PEDAL RETURN
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at fast idle whilst making sev-
eral brake applications.
2 Pull the brake pedal upwards.
3 Release the brake pedal and measure the dis-
tance from the rubber to the floor.
4 Make a hard brake application.

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206-00-8 Brake System - General Information 206-00-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Release the brake pedal and measure the dis-
tance from brake pedal rubber to the floor. The
brake pedal should return to its original posi-
tion.
• Does the brake pedal return to its original posi-
tion?
→ Yes
Vehicle is OK.
→ No
GO to C2
C2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal to make sure it is oper-
ating freely.
• Is the brake pedal operating freely?
→ Yes
INSTALL a new brake booster. REFER to
Section 206-07. TEST the system for nor-
mal operation.
→ No
REPAIR or INSTALL new brake pedal and
bracket. TEST the system for normal opera-
tion.

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206-00-9 Brake System - General Information 206-00-9

DIAGNOSIS AND TESTING

feels spongy, bleed the brake system. Refer

to General Procedures.
Component Tests
Brake Master Cylinder
Brake Booster Usually, the first and strongest indicator of
1. Inspect all hoses and connections. All anything wrong in the brake system is a feeling
unused vacuum connectors should be through the brake pedal. In diagnosing the
capped. Hoses and their connections should condition of the brake master cylinder, check
be correctly secured and in good condition brake pedal feel as evidence of a brake concern.
with no holes and no collapsed areas. Check for brake warning indicator illumination
Inspect the brake booster check valve for and the brake fluid level in the brake fluid
damage. reservoir.
2. Check the hydraulic brake system for leaks
or low fluid.
Normal Conditions
3. With the transmission in PARK (automatic
transmission), stop the engine and operate The following conditions are considered normal
the parking brake. Operate the brake pedal and are not indications that the brake master
several times to exhaust all vacuum in the cylinder is in need of repair.
system.
1. New brake systems are not designed to
4. With the engine turned OFF and all vacuum produce as hard a pedal effort as in the past.
in the system exhausted operate the brake Complaints of light pedal efforts should be
pedal and hold it down. Start the engine. If compared to pedal efforts of another vehicle,
the vacuum system is operating, the brake same model and year.
pedal will tend to move downward under 2. During normal operation of the brake master
constant foot pressure. If no motion is felt,
cylinder, the brake fluid level in the reservoir
the vacuum booster system is not
will rise during brake application and fall
functioning.
during release. The net brake fluid level (after
5. Remove the vacuum hose from the brake brake application and release) will remain
booster. Manifold vacuum should be unchanged.
available at the brake booster end of the
3. A trace of brake fluid exists on the brake
hose with the engine at idle speed and the
booster shell below the master cylinder
transmission in PARK or NEUTRAL. Make
mounting flange. This results from the normal
sure that all unused vacuum outlets are
lubricating action of the master cylinder bore
correctly capped, hose connectors are
end seal.
correctly secured and vacuum hoses are in
good condition. When it is established that 4. Brake fluid level will fall with brake pad wear.
manifold vacuum is available to the brake
booster, connect the vacuum hose to the Abnormal Conditions
brake booster and repeat Step 3. If no
downward movement of the brake pedal is Changes in brake pedal feel or travel are
felt, the vacuum booster system is not indicators that something could be wrong in the
functioning. brake system. The diagnostic procedure and
techniques are brake pedal feel, brake warning
6. Run the engine for a minimum of 10 seconds
indicator illumination and low brake fluid level as
at fast idle. Stop the engine and let the
indicators in diagnosing brake system concerns.
vehicle stand for 10 minutes. Then, operate
The following condition are considered abnormal
the brake pedal with approximately 98N (20
and indicate that the brake master cylinder is in
lb) of force. The pedal feel (brake
need of repair.
applications) should be the same as noted
with the engine running. If the brake pedal
feels hard (no power assist), install a new
check valve and then repeat the testing. If
the brake pedal still feels hard, install a new
brake booster. If the brake pedal movement

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206-00-10 Brake System - General Information 206-00-10

DIAGNOSIS AND TESTING (Continued)

1. Brake pedal goes down fast. This could be Non-Pressure Leaks
caused by an external or internal leak.
Any empty brake fluid reservoir condition may be
2. Brake pedal eases down slowly. This could the result of two types of non-pressure external
be caused by an external or internal leak. leaks.
3. Brake pedal is low or feels spongy. This
Type 1: An external leak may occur at the brake
condition may be caused by no fluid in the
fluid reservoir cap because of incorrect
brake master cylinder reservoir, brake fluid
positioning of the gasket and cap.
reservoir cap vent holes blocked or air in the
hydraulic system. Reposition the gasket and cap.
4. Brake pedal effort is excessive. This may be Type 2: An external leak may occur at the brake
caused by a bind or obstruction in pedal or fluid reservoir mounting seals. Repair such a leak
linkage, blocked fluid control valve or by installing new seals.
insufficient brake booster vacuum.
5. Rear brakes lock up during light pedal force.
This may be caused by grease or fluid on
brake pads, damaged brake pads and
linings, incorrectly adjusted parking brakes,
damaged or contaminated brake pressure
control valve.
6. Brake pedal effort is erratic. This condition
could be caused by the brake booster being
in operative, extreme brake caliper piston
knock back or incorrectly installed brake
pads.
7. Brake warning indicators is always ON. This
may be caused by low fluid level, ignition
wire routing too close to the fluid level
indicator, or float assembly damage.

Bypass Condition Test

1. Check the brake fluid level in the brake fluid
reservoir. Fill the brake fluid reservoir to the
MAX mark if low or empty.
2. Observe the brake fluid level in the brake
fluid reservoir. If after several brake
applications, the brake fluid level remains the
same, measure the wheel turning torque
required to rotate the wheels with rearward
with brakes applied as follows:
Place the transmission in NEUTRAL and raise
and support the vehicle. REFER to Section
100-02.
With the aid of another technician, operate the
brakes with a minimum of 445N (100 lb) and hold
for approximately 15 seconds. With the brakes
still applied, exert torque on the front wheels to
10.1 Nm (75 lbf.ft). If either wheel rotates, install
a new brake master cylinder.

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206-00-11 Brake System - General Information 206-00-11

DIAGNOSIS AND TESTING

Emergency Brake Assist (EBA)

Principles of Operation Inspection and Verification

All critical braking situations are immediately 1. Verify the customer concern.
detected by the hydraulic mechanism 2. Visually inspect for obvious signs of
incorporated in the brake master cylinder that is mechanical damage.
sensitive to the effect and speed of application of
the brake pedal. Visual Inspection Chart
When activated, this has an immediate affect on Mechanical
the pressure distribution in the brake master
• Tire pressures
cylinder and allows for the generation of high
pressure braking levels with a reduced brake • Wheels and tires
pedal effort. The brake system pressure is • Brake line damage
modulated by slightly releasing the brake pedal. • Fluid leaks
When the brake pedal pressure is reduced below • Fluid level
its threshold value, the EBA system is
deactivated. • Fluid contamination
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.

Condition Possible Sources Action

• The emergency brake assist • Brake assist valve. • CARRY OUT the emergency
(EBA) is inoperative brake assist (EBA) function tests
in this section.
and does not indicate that the brake master
cylinder is in need of renewal.
Function Tests

Dynamic Diagnosis
Static Diagnosis
To simulate an emergency braking situation:
To simulate normal braking:
1. Carry out a road test at a speed of 40-50
1. Run the engine for 30 seconds. km/h (25-30 mph).
2. Depress the brake pedal slowly with 2. Simulate an emergency braking situation
maximum pedal effort to just beyond the using a low pedal force (wait at least 30
pressure point and hold. seconds before repeating the test).
3. Hold the brake pedal in this position for a 3. The anti-lock brake system (ABS) will be
minimum of 10 seconds. activated with the aid of the EBA.
4. Release the brake pedal by half of the pedal 4. The brake pedal can modulate the brake
travel and pulsate the pedal. system pressure.
5. If the resistance in the brake pedal is low (the 5. If the resistance in the brake pedal is low (the
pedal feels soft), then the system has pedal feels soft), then the system has
switched to EBA mode and is operating switched to EBA mode and is operating
correctly. This condition is considered normal correctly. This condition is considered normal

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206-00-12 Brake System - General Information 206-00-12

DIAGNOSIS AND TESTING (Continued)

and does not indicate that the brake master
cylinder is in need of renewal.
If only the static diagnosis was successful, then
the brake pedal was not depressed rapidly
enough during the dynamic diagnosis. If both the
static and dynamic diagnosis were unsuccessful,
check that the brake booster is operating
correctly before installing a new EBA brake
master cylinder. REFER to Section 206-06.

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206-00-13 Brake System - General Information 206-00-13

GENERAL PROCEDURES

Brake System Bleeding (12 141 0)

GENERAL PROCEDURES

8. Continue operating the brake pedal until

air-free fluid is being pumped into the
Bleeding bleed jar.
Vehicles with anti-lock brakes 9. With the brake pedal fully depressed
1. Disconnect the battery ground cable. For tighten the bleed nipple.
additional information, refer to Section
414-01. 10. CAUTION: Make sure the bleed nipple
cap is installed after bleeding the
All Vehicles brake line(s). This will prevent
WARNING: Brake fluid contains corrosion to the bleed nipple. Failure
polyglycol ethers and polyglycols. Avoid to follow this instruction may result in
contact with the eyes. Wash hands the bleed nipple becoming seized.
thoroughly after handling. If brake fluid Repeat the procedure for the remaining
contacts the eyes, flush the eyes for 15 brake lines.
minutes with cold running water. Get
medical attention if irritation persists. If
taken internally, drink water and induce
vomiting. Get medical attention
immediately. Failure to follow these
instructions may result in personal
injury.
CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold
water.
NOTE: Make sure that the vehicle is standing on
a level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
2. CAUTION: The brake fluid reservoir
must remain full with new, clean brake
fluid at all times during bleeding.
Install the bleed tube to the bleed nipple.
3. Immerse the end of the bleed tube in a
bleed jar containing a small quantity of
approved brake fluid.
4. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
5. Loosen the bleed nipple by one-half turn.
6. Operate the brake pedal fully (pumping
brake fluid and air into the bleed jar) and
allow the brake pedal to return to the rest
position.
7. Fill the brake fluid reservoir.

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206-03-1 Front Disc Brake 206-03-1

SECTION 206-03 Front Disc Brake

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-03-2

DESCRIPTION AND OPERATION

Front Disc Brake................................................................................................................ 206-03-3

DIAGNOSIS AND TESTING

Front Disc Brake................................................................................................................ 206-03-4

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206-03-2 Front Disc Brake 206-03-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Super DOT 4 brake fluid ESD-M6C57-A
High temperature grease ESE-M12A4-A

Front Disc Brake Specification

mm inches
Brake disc diameter 300 11.81
New brake disc nominal thickness 24 0.945
Worn brake disc discard thickness* 22.0 0.866
Maximum brake disc thickness variation 0.015 0.0006
Worn brake pad discard thickness* 1.5 0.06
* When the discard thickness has been reached, install a new brake disc/brake pads.

Torque Specifications
Description Nm lb-ft lb-in
Brake caliper anchor plate retaining bolts 130 96 –
Brake caliper retaining bolts 30 22 –
Brake hose to brake caliper union 10 7 89

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206-03-3 Front Disc Brake 206-03-3

DESCRIPTION AND OPERATION

Front Disc Brake

DESCRIPTION AND OPERATION

Item Part Description

Number
1 Wheel hub
2 Brake disc
3 Brake disc retaining washer
4 Brake caliper anchor plate
5 Brake caliper
6 Brake pads
Brake Disc
Vehicles with steel wheels are equipped with
standard brake discs and vehicles with alloy
wheels are equipped with anti-corrosion coated
brake discs.

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206-03-4 Front Disc Brake 206-03-4

DIAGNOSIS AND TESTING

Front Disc Brake

DIAGNOSIS AND TESTING

REFER to Section 206-00.

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206-04-1 Rear Disc Brake 206-04-1

SECTION 206-04 Rear Disc Brake

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-04-2

DESCRIPTION AND OPERATION

Rear Disc Brake ................................................................................................................ 206-04-3

DIAGNOSIS AND TESTING

Rear Disc Brake ................................................................................................................ 206-04-4

REMOVAL AND INSTALLATION

Brake Pads................................................................................................... (12 238 0) 206-04-5

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206-04-2 Rear Disc Brake 206-04-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Super DOT 4 brake fluid ESD-M6C57-A
High temperature grease ESE-M12A4-A

Rear Disc Brake Specification

Description mm inches
Brake disc diameter 280 11.02
New brake disc nominal thickness 12 0.472
Worn brake disc discard thickness* 10.2 0.401
Maximum brake disc thickness variation 0.015 0.0006
Worn brake pad discard thickness* 1.5 0.059
* When the discard thickness has been reached, install a new brake disc/brake pads.

Torque Specifications
Description Nm lb-ft lb-in
Brake caliper anchor plate retaining bolts 80 59 –
Brake caliper retaining bolts 30 22 –
Brake hose to brake caliper union 10 7 89
Wheel spindle retaining bolts 90 66 –

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206-04-3 Rear Disc Brake 206-04-3

DESCRIPTION AND OPERATION

Rear Disc Brake

DESCRIPTION AND OPERATION

Item Part Description

Number
1 Brake caliper
2 Brake pads
3 Brake caliper anchor plate
4 Wheel hub
5 Brake disc shield
6 Brake disc retaining washer
7 Brake disc
Brake Disc
Vehicles with steel wheels are equipped with
standard brake discs and vehicles with alloy
wheels are equipped with anti-corrosion coated
brake discs.

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206-04-4 Rear Disc Brake 206-04-4

DIAGNOSIS AND TESTING

Rear Disc Brake

DIAGNOSIS AND TESTING

REFER to Section 206-00.

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206-04-5 Rear Disc Brake 206-04-5

REMOVAL AND INSTALLATION

Brake Pads (12 238 0)

REMOVAL AND INSTALLATION

3. Detach the parking brake cable from the

brake caliper.
Name Specification 1. Depress the locking tangs.
2. Detach the cable from the brake caliper.
Super DOT 4 brake ESD-M6C57-A
fluid
High temperature ESE-M12A4-A
grease

Removal
All vehicles
CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold
water.
1. Remove the wheel and tire. For additional
information, refer to Section 204-04. 4. Remove the brake caliper lower retaining
2. Detach the parking brake cable from the bolt.
brake caliper lever.
1. Push the caliper lever.
2. Detach the parking brake cable.

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206-04-6 Rear Disc Brake 206-04-6

REMOVAL AND INSTALLATION (Continued)

Wagon 4-door and 5-door
5. CAUTION: When the brake caliper 7. CAUTION: When the brake caliper
piston is retracted into the piston piston is retracted into the piston
housing, brake fluid will be displaced housing, brake fluid will be displaced
into the brake fluid reservoir. into the brake fluid reservoir.
CAUTION: Support the brake caliper CAUTION: Support the brake caliper
against the brake pad and disc assembly against the brake pad and disc assembly
during brake caliper piston retraction. during brake caliper piston retraction.
NOTE: To retract the left-hand brake caliper NOTE: To retract the left-hand brake caliper
piston, the piston must be rotated clockwise piston, the piston must be rotated
whilst applying pressure. counterclockwise whilst applying pressure.
Using a suitable Allen key, retract the Using a suitable Allen key, retract the
brake caliper piston. brake caliper piston.

6. NOTE: To retract the right-hand brake caliper 8. NOTE: To retract the right-hand brake caliper
piston, the piston must be rotated piston, the piston must be rotated clockwise
counterclockwise whilst applying pressure. whilst applying pressure.
Using a suitable Allen key, retract the Using a suitable Allen key, retract the
brake caliper piston. brake caliper piston.

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206-04-7 Rear Disc Brake 206-04-7

REMOVAL AND INSTALLATION (Continued)

All vehicles Installation

9. Centralize the indent on the left hand brake
caliper piston. All vehicles
1. Install the brake pads (caliper shown
removed for clarity).
• Apply high temperature grease to the brake
pad contact points

10. Centralize the indent on the right hand

brake caliper piston.

2. Install the brake caliper lower retaining

bolt.

11. NOTE: Rotate the brake caliper upwards.

Remove the brake pads (caliper shown
removed for clarity)
3. Attach the parking brake cable to the brake
caliper.

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206-04-8 Rear Disc Brake 206-04-8

REMOVAL AND INSTALLATION (Continued)

4. Attach the parking brake cable to the brake
caliper lever.
1. Push the caliper lever.
2. Attach the cable to the lever.

5. Install the wheel and tire. For additional

information, refer to Section 204-04.
6. Depress the brake pedal, check the fluid
level in the brake fluid reservoir and top up
if necessary with brake fluid.

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206-05-1 Parking Brake and Actuation 206-05-1

SECTION 206-05 Parking Brake and Actuation

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-05-2

DESCRIPTION AND OPERATION

Parking Brake.................................................................................................................... 206-05-3

DIAGNOSIS AND TESTING

Parking Brake.................................................................................................................... 206-05-4

Inspection and Verification ............................................................................................... 206-05-4
Symptom Chart ................................................................................................................ 206-05-4
Pinpoint Tests .................................................................................................................. 206-05-4

REMOVAL AND INSTALLATION

Parking Brake Control .................................................................................. (12 664 0) 206-05-6

Parking Brake Cable..................................................................................... (12 675 0) 206-05-12

08/2002 2003.0 Mondeo

206-05-2 Parking Brake and Actuation 206-05-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Parking brake control retaining nuts 20 15 –

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206-05-3 Parking Brake and Actuation 206-05-3

DESCRIPTION AND OPERATION

Parking Brake
DESCRIPTION AND OPERATION

Item Part Description

Number
1 Parking brake control
2 Equalizer
3 Parking brake cables

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206-05-4 Parking Brake and Actuation 206-05-4

DIAGNOSIS AND TESTING

Parking Brake
DIAGNOSIS AND TESTING

Mechanical Electrical
• Parking brake • Parking brake warn-
Inspection and Verification control. ing circuit.
1. Verify the customer concern. • Parking brake ca-
2. Visually inspect for obvious signs of ble(s)
mechanical or electrical damage. 3. If an obvious cause for an observed or
reported concern is found, correct the cause
Visual Inspection Chart (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.
Symptom Chart

Condition Possible Sources Action

• The parking brake will not apply • Parking brake control. • GO to Pinpoint Test A.
• Parking brake cable(s).
• The parking brake will not re- • Parking brake control. • GO to Pinpoint Test B.
lease • Parking brake cable(s).

Pinpoint Tests
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE PARKING BRAKE CABLE ADJUSTMENT
1 Carry out the parking brake cable adjustment
procedure. REFER to Parking Brake Cable Ad-
justment in this section.
• Does the parking brake now engage correctly?
→ Yes
Parking brake is OK.
→ No
GO to A2
A2: CHECK THE PARKING BRAKE CABLE(S)
1 Inspect the parking brake cable(s) for damage,
rust or fraying.
• Are the parking brake cable(s) OK?
→ Yes
GO to A3
→ No
REPAIR or INSTALL new cables as neces-
sary. REFER to Parking Brake Cable in this
section. TEST the system for normal opera-
tion.
A3: CHECK THE BRAKE PADS
1 Check the brake pads for excessive wear.

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206-05-5 Parking Brake and Actuation 206-05-5

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the brake pads OK?

→ Yes
INSPECT for other causes such as loose
parking brake control or other brake system
components. REFER to Section 206-04 /
206-05. TEST the system for normal opera-
tion.
→ No
INSTALL new brake pads. REFER to Sec-
tion 206-04.TEST the system for normal op-
eration.
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE PARKING BRAKE CONTROL
1 Release the parking brake control by pulling
upwards on the control lever and pushing the
release button.
• Did the parking brake release?
→ Yes
GO to B2
→ No
INSTALL a new parking brake control.
REFER to Parking Brake Control in this sec-
tion. TEST the system for normal operation.
B2: CHECK THE PARKING BRAKE CABLE(S)
1 Raise and Support the vehicle on a free-wheel
lift. REFER to Section 100-02.
2 Loosen the parking brake cable tension at the
parking brake equalizer.
3 Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
→ Yes
INSPECT other brake system components,
REPAIR or INSTALL new components as
necessary. REFER to Section 206-04 / 206-
05. TEST the system for normal operation.
→ No
INSTALL new parking brake cables.
REFER to Parking Brake Cable in this sec-
tion. TEST the system for normal operation.

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206-05-6 Parking Brake and Actuation 206-05-6

REMOVAL AND INSTALLATION

Parking Brake Control (12 664 0)

REMOVAL AND INSTALLATION

Vehicles with diesel engine

5. CAUTION: Over bending of the exhaust
Name Specification flexible pipe may cause damage
Anti-seize grease SAM-1C107A resulting in failure.
Support the exhaust flexible pipe with a
support wrap or suitable splint.
Removal
All vehicles
1. Release the parking brake.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with 1.8L or 2.0L engine
3. Detach the catalytic converter from the
front muffler pipe.
• Discard the gasket and nuts.

6. Detach the exhaust flexible pipe from the

front muffler pipe.
• Discard the sealing ring and nuts.

Vehicles with 2.5L engine

4. Detach the catalytic converter from the
front muffler pipe.
• Discard the gasket and nuts.

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206-05-7 Parking Brake and Actuation 206-05-7

REMOVAL AND INSTALLATION (Continued)

All vehicles
Vehicles with 2.5L engine
7. Detach the front and rear muffler assembly
10. Remove the front and rear muffler
from the front exhaust hanger insulator.
assembly.
• Detach the rear mufflers from the rear ex-
haust hanger insulators (left-hand shown,
right-hand similar).

8. NOTE: Support the front and rear muffler with

a suitable axle stand.
Detach the front and rear muffler assembly
from the intermediate exhaust hanger All vehicles
insulator. 11. Remove the exhaust heat shield.

Vehicles with 1.8L, 2.0L or diesel engine 12. Disconnect the parking brake cables from
9. Remove the front and rear muffler the equalizer.
assembly.
• Detach the muffler from the rear exhaust
hanger insulator.

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206-05-8 Parking Brake and Actuation 206-05-8

REMOVAL AND INSTALLATION (Continued)

13. Detach the parking brake control from the Installation
underside of the floor pan.
All vehicles
1. Install the parking brake control.
• Pass the parking brake cable and equalizer
through the opening in the floor pan.

14. Lower the vehicle.

15. Remove the floor console. For additional
information, refer to Section 501-12.
16. Disconnect the parking brake warning
indicator switch electrical connector. 2. Connect the parking brake warning indica-
tor switch electrical connector.

17. Remove the parking brake control.

3. Install the floor console. For additional
• Pull the parking brake cable and equalizer
information, refer to Section 501-12.
through the opening in the floor pan.
4. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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206-05-9 Parking Brake and Actuation 206-05-9

REMOVAL AND INSTALLATION (Continued)

5. Attach the parking brake control to the un- 7. NOTE: To aid installation, the parking brake
derside of the floor pan. control self adjuster mechanism is locked out
by a small clock spring.
NOTE: Make sure the parking brake control lever
is in the fully released position.
Release the parking brake control self
adjusting mechanism clock spring.
1. Sharply pull the equalizer rearwards.
2. Release the equalizer.

6. Connect the parking brake cables to the

equalizer.

8. Install the exhaust heat shield.

G37395 en 08/2002 2003.0 Mondeo

206-05-10 Parking Brake and Actuation 206-05-10

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.5L engine All vehicles
9. Install the front and rear muffler assembly. 11. Attach the front and rear muffler assem-
• Attach the rear mufflers to the rear exhaust bly to the intermediate exhaust hanger
hanger insulators (left-hand shown, right- insulator.
hand similar).

12. Attach the front and rear muffler assem-

Vehicles with 1.8L, 2.0L or diesel engine bly to the front exhaust hanger insulator.
10. Install the front and rear muffler
assembly.
• Attach the muffler to the rear exhaust
hanger insulator.

Vehicles with diesel engine

13. NOTE: Coat the front muffler pipe studs with
anti-seize grease.
NOTE: Install new sealing ring and nuts.
Attach the exhaust flexible pipe to the
front muffler pipe.

G37395 en 08/2002 2003.0 Mondeo

206-05-11 Parking Brake and Actuation 206-05-11

REMOVAL AND INSTALLATION (Continued)

14. Remove the exhaust wrap or splint.

Vehicles with 2.5L engine
15. NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install new gasket and nuts.
Attach the catalytic converter to the front
muffler pipe.

Vehicles with 1.8L or 2.0L engine

16. NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install new gasket and nuts.
Attach the catalytic converter to the front
muffler pipe.

All vehicles
17. Lower the vehicle.
18. Adjust the parking brake cable.

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206-05-12 Parking Brake and Actuation 206-05-12

REMOVAL AND INSTALLATION

Parking Brake Cable (12 675 0)

Removal 5. Detach the muffler and tailpipe assembly

from the chassis.
1. Release the parking brake.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
3. CAUTION: Over bending of the exhaust
flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a
support wrap or suitable splint.

6. Remove the muffler and tailpipe assembly.

• Discard the gasket and nuts.

4. Detach the muffler and tailpipe assembly

from the chassis.

7. Remove the exhaust heat shield.

G37396 en 08/2002 2003.0 Mondeo

206-05-13 Parking Brake and Actuation 206-05-13

REMOVAL AND INSTALLATION (Continued)

8. Detach the tie bar bracket cover. 11. Remove the brake cable from the equal-
izer

9. Detach the parking brake cable from the

brake caliper lever. 12. Detach the parking brake cable from the
1. Push the caliper lever. chassis.
2. Detach the parking brake lever. 1. Depress the locking tangs.
2. Detach the cable from the chassis.

10. Detach the parking brake cable from the

brake caliper. 13. Remove the parking brake cable.
1. Depress the locking tangs.
2. Detach the cable from the brake caliper.

Installation
1. To install, reverse the removal procedure.

G37396 en 08/2002 2003.0 Mondeo

206-05-14 Parking Brake and Actuation 206-05-14

REMOVAL AND INSTALLATION (Continued)

2. To adjust the parking brake cable, operate
the parking brake control several times.

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206-06-1 Hydraulic Brake Actuation 206-06-1

SECTION 206-06 Hydraulic Brake Actuation

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-06-2

DESCRIPTION AND OPERATION

Hydraulic Brake Actuation ................................................................................................. 206-06-3

DIAGNOSIS AND TESTING

Hydraulic Brake Actuation ................................................................................................. 206-06-5

REMOVAL AND INSTALLATION

Brake Pedal and Bracket ................................................................................................... 206-06-6

Brake Master Cylinder .................................................................................. (12 343 0) 206-06-9
Brake Pedal Cross-Shaft .............................................................................. (12 338 0) 206-06-11
Brake Pedal Control Switch ............................................................................................... 206-06-13

08/2002 2003.0 Mondeo

206-06-2 Hydraulic Brake Actuation 206-06-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Super DOT 4 brake fluid ESD-M6C57-A

Torque Specifications
Description Nm lb-ft lb-in
Brake master cylinder retaining nuts 20 15 –
Brake tube to brake master cylinder union 20 15 –
Brake pedal bracket retaining nuts 25 18 –
Brake booster retaining nuts 20 15 –

G37402 en 08/2002 2003.0 Mondeo

206-06-3 Hydraulic Brake Actuation 206-06-3

DESCRIPTION AND OPERATION

Hydraulic Brake Actuation

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 Front brake hoses
1 Rear brake hoses
4 Brake master cylinder
2 Brake hydraulic tubes
5 Brake fluid reservoir

Standard Brake Master Cylinder

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206-06-4 Hydraulic Brake Actuation 206-06-4

DESCRIPTION AND OPERATION (Continued)

Brake Master Cylinder - Fitted with EBA System

G37398 en 08/2002 2003.0 Mondeo

206-06-5 Hydraulic Brake Actuation 206-06-5

DIAGNOSIS AND TESTING

Hydraulic Brake Actuation

DIAGNOSIS AND TESTING

REFER to Section 206-00.

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206-06-6 Hydraulic Brake Actuation 206-06-6

REMOVAL AND INSTALLATION

Brake Pedal and Bracket

REMOVAL AND INSTALLATION

Removal 3. Detach the brake booster actuating rod

from the brake pedal.
Vehicles with manual transaxle
1. CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold
water.
NOTE: Cap the clutch hydraulic pipes to prevent
fluid loss or dirt ingress.
Disconnect the clutch hydraulic pipes from
the clutch master cylinder.

4. Remove the brake pedal position (BPP)

switch. For additional information, refer to
Brake Pedal Control Switch in this section.
Vehicles with manual transaxle
5. Detach the clutch pedal position switch
from the brake pedal bracket.

All vehicles
2. Remove the instrument panel lower panel.
1. Remove the retaining screws.
2. Release the retaining clip.

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206-06-7 Hydraulic Brake Actuation 206-06-7

REMOVAL AND INSTALLATION (Continued)

All vehicles 9. Remove the brake pedal bracket retaining

6. Detach the BPP switch electrical harness nuts from the engine compartment.
from the brake pedal bracket.

Left-hand drive vehicles

7. Detach the accelerator cable from the ac- 10. Detach the brake pedal bracket from the
celerator pedal. floor pan.

Right-hand drive vehicles All vehicles

8. Remove the brake pedal bracket retaining 11. Remove the brake pedal and bracket.
nuts from inside the vehicle.

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206-06-8 Hydraulic Brake Actuation 206-06-8

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Install a new BPP switch retaining clip.
To install, reverse the removal procedure.
2. Bleed the clutch system.

G37399 en 08/2002 2003.0 Mondeo

206-06-9 Hydraulic Brake Actuation 206-06-9

REMOVAL AND INSTALLATION

Brake Master Cylinder (12 343 0)

Removal 4. NOTE: It will be necessary to carry out this

step on both sides in order to completely drain
All vehicles the brake fluid reservoir.
CAUTION: If brake fluid is spilt on the Drain the brake fluid reservoir.
paintwork, the affected area must be 1. Connect one end of a suitable piece of
immediately washed down with cold clear plastic pipe to the bleed nipple and
water. place the other end into a suitable
1. Disconnect the brake vacuum pipe from container.
the brake booster.
2. Loosen the bleed nipple.
1. Unclip the brake vacuum pipe.
3. Depress the brake pedal until all of the
2. Disconnect the brake vacuum pipe. brake fluid is drained from the brake fluid
reservoir.
4. Tighten the bleed nipple.

2. Disconnect the low brake fluid warning in-

dicator switch electrical connector.
Vehicle with manual transaxle
5. CAUTION: Cap the clutch master
cylinder hose to prevent fluid loss or
dirt ingress.
Disconnect the clutch master cylinder
hose from the brake fluid reservoir.

3. CAUTION: The brake fluid reservoir

cap must not become contaminated.
Remove the brake fluid reservoir cap.

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206-06-10 Hydraulic Brake Actuation 206-06-10

REMOVAL AND INSTALLATION (Continued)

All vehicles
6. CAUTION: Cap the brake tubes to
prevent fliud loss or dirt ingress.
Disconnect the brake tubes from the brake
master cylinder.

7. Remove the brake master cylinder and

brake fluid reservoir assembly.

Installation
WARNING: Do not install a standard
brake master cylinder to a vehicle
equiped with Emergency Brake Assist.
Failure to follow this instruction may
result in personal injury.
CAUTION: Make sure the brake master
cylinder vacuum seal is correctly
positioned before installation.
1. To install, reverse the removal procedure.
2. Bleed the brake system. For additional
information, refer to Section 206-00.

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206-06-11 Hydraulic Brake Actuation 206-06-11

REMOVAL AND INSTALLATION

Brake Pedal Cross-Shaft (12 338 0)

Removal 4. Loosen the brake booster bracket retain-

ing nuts.
1. Remove the brake booster. For additional
information, refer to Section 206-07.
2. De-tension the brake pedal cross shaft
return spring.
• Unclip the spring.

5. Remove the brake pedal bracket retaining

nuts.

3. Remove the brake booster actuator rod

retaining nut.

6. Remove the brake pedal cross shaft

bracket retaining nut.

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206-06-12 Hydraulic Brake Actuation 206-06-12

REMOVAL AND INSTALLATION (Continued)

7. Position the brake booster bracket to one
side.

8. Remove the brake pedal cross shaft.

1. Move the cross shaft to the right.
2. Pull the cross shaft forward

Installation
1. To install, reverse the removal procedure.

G37401 en 08/2002 2003.0 Mondeo

206-06-13 Hydraulic Brake Actuation 206-06-13

REMOVAL AND INSTALLATION

Brake Pedal Control Switch

Removal
1. Remove and discard the brake pedal posi- Installation
tion (BPP) switch retaining clip.
1. CAUTION: Make sure the BPP switch
retaining clip is correctly positioned
before installation.
Install a new BPP switch retaining clip.

2. Disconnect the BPP switch electrical con-

nector.

2. Set the BPP switch.

• Pull the switch plunger out to its full extent.

3. Remove the BPP switch.

1. Unlock the switch.
2. Remove the switch.

3. Depress the brake pedal and hold it in the

depressed position.

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206-06-14 Hydraulic Brake Actuation 206-06-14

REMOVAL AND INSTALLATION (Continued)

4. CAUTION: The BPP switch is

automatically adjusted during
installation.
Install the BPP switch.
1. Install the switch.
2. Lock the switch in position.

5. Release the brake pedal.

6. Connect the BPP switch electrical connec-
tor.

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206-07-1 Power Brake Actuation 206-07-1

SECTION 206-07 Power Brake Actuation

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-07-2

DESCRIPTION AND OPERATION

Brake Booster.................................................................................................................... 206-07-3

Right-hand drive shown.................................................................................................... 206-07-3

DIAGNOSIS AND TESTING

Power Brake System ......................................................................................................... 206-07-4

REMOVAL AND INSTALLATION

Brake Booster............................................................................................... (12 451 0) 206-07-5

Brake Vacuum Pump.................................................................................... (12 414 0) 206-07-7

08/2002 2003.0 Mondeo

206-07-2 Power Brake Actuation 206-07-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Brake booster retaining nuts 20 15 –
Brake pedal bracket retaining nuts 25 18 –
Cross-shaft bracket retaining nuts 25 18 –

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206-07-3 Power Brake Actuation 206-07-3

DESCRIPTION AND OPERATION

Brake Booster
DESCRIPTION AND OPERATION

WARNING: Do not install a standard

brake master cylinder to a vehicle
equipped with Emergency Brake Assist.
Failure to follow this instruction may
result in personal injury.

Right-hand drive shown

Item Part Description

Item Part Description Number
Number
7 Cross shaft
1 Cross shaft support bracket
2 Brake booster actuation rod
3 Brake booster
4 Brake booster support
bracket
5 Brake master cylinder
6 Label (vehicles equipped
with emergency brake as-
sist)

G37403 en 08/2002 2003.0 Mondeo

206-07-4 Power Brake Actuation 206-07-4

DIAGNOSIS AND TESTING

Power Brake System

DIAGNOSIS AND TESTING

REFER to Section 206-00.

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206-07-5 Power Brake Actuation 206-07-5

REMOVAL AND INSTALLATION

Brake Booster (12 451 0)

REMOVAL AND INSTALLATION

Removal 4. Detach the strut and spring assembly top

mount brace from the cowl.
All vehicles
1. Remove the brake master cylinder. For
additional information, refer to Section
206-06.
2. Remove the strut and spring assembly top
mount brace cover.

5. Remove the strut and spring assembly top

mount brace.

3. Detach the strut and spring assembly top

mount from the strut and spring assembly
top mount brace.

6. Detach the brake booster from the brake

booster bracket.

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206-07-6 Power Brake Actuation 206-07-6

REMOVAL AND INSTALLATION (Continued)

Right-hand drive vehicles Installation
7. Detach the brake booster from the brake
pedal cross shaft. 1. WARNING: Do not install a normal
• Remove the pin. brake booster to a vehicle fitted with
Emergency Brake Assist. Failure to
follow this instruction may cause
personal injury.
To install, reverse the removal procedure.

Left-hand drive vehicles

8. Remove the brake booster actuator retain-
ing clip.

9. Remove the brake booster retaining nuts.

All vehicles
10. Remove the brake booster.

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206-07-7 Power Brake Actuation 206-07-7

REMOVAL AND INSTALLATION

Brake Vacuum Pump (12 414 0)

4. Detach the power steering line support
bracket from the brake vacuum pump.
Special Tool(s)
Remover/Install, Cooling
Hose Clamp
303-097 (24-003)

Removal
1. Remove the engine upper cover

5. Disconnect the positive crankcase ventila-

tion (PCV) hose from the valve cover.

2. Drain the cooling system. For additional

information, refer to Section 303-03.
3. Disconnect and unclip the cylinder head
temperature (CHT) sensor electrical con-
nector from the power steering line sup- 6. Disconnect the vacuum hose from the
port bracket. brake vacuum pump.

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206-07-8 Power Brake Actuation 206-07-8

REMOVAL AND INSTALLATION (Continued)

7. Using the special tool, disconnect the 10. Remove the brake vacuum pump.
coolant expansion tank hose from the • Discard the gasket.
brake vacuum pump.

8. Disconnect the exhaust gas recirculation

(EGR) cooler coolant hose from the ther- Installation
mostat housing.
1. CAUTION: Make sure the drive
coupling is aligned with the camshaft
coupling.
NOTE: Install a new brake vacuum pump gasket.
NOTE: Install a new thermostat housing O-ring
seal.
To install, reverse the removal procedure.

9. Detach the thermostat housing from the

brake vacuum pump.
• Discard the O-ring seal.

G37405 en 08/2002 2003.0 Mondeo

206-09A-1 Anti-Lock Control 206-09A-1

SECTION 206-09A Anti-Lock Control

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-09-2

DESCRIPTION AND OPERATION

Anti-Lock Control ............................................................................................................... 206-09-3

DIAGNOSIS AND TESTING

Anti-Lock Control ............................................................................................................... 206-09-4

Inspection and Verification ............................................................................................... 206-09-4

REMOVAL AND INSTALLATION

Hydraulic Control Unit (HCU)............................................................................................. 206-09-5

08/2002 2003.0 Mondeo

206-09A-2 Anti-Lock Control 206-09A-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Super DOT 4 brake fluid ESD-M6C57-A

Torque Specifications
Description Nm lb-ft lb-in
Hydraulic control unit (HCU) support bracket re- 25 18 -
taining nuts
Brake tube to HCU union 15 11 -
Brake tube in-line unions 17 13 -
Front wheel speed sensor retaining bolt 5 4 44

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206-09A-3 Anti-Lock Control 206-09A-3

DESCRIPTION AND OPERATION

Anti-Lock Control
DESCRIPTION AND OPERATION

Item Part Description

Number
1 Hydraulic control unit (HCU)
2 Rear wheel speed sensor
3 Front wheel speed sensor

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206-09A-4 Anti-Lock Control 206-09A-4

DIAGNOSIS AND TESTING

Anti-Lock Control
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 206-09A for

schematic and connector information.

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
• Wheel speed • Fuse(s)
sensor(s) • Electrical
• Wheel speed sen- connector(s)
sor ring(s) • Wiring harness(s).
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 cause is not visually evident, verify the
symptom and refer to WDS.

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206-09A-5 Anti-Lock Control 206-09A-5

REMOVAL AND INSTALLATION

Hydraulic Control Unit (HCU)

REMOVAL AND INSTALLATION

Removal
6. CAUTION: Cap the brake tubes to
CAUTION: If brake fluid is spilt on the prevent fluid loss or dirt ingress.
paintwork, the affected area must be NOTE: Make a note of the position of the brake
immediately washed down with cold tubes to aid installation.
water.
Disconnect the brake tubes from the HCU.
1. Disconnect the battery ground cable.
For additional information, refer to Section
414-01.
2. Remove the air cleaner.
3. Remove the brake booster. For
additional information, refer to Section
206-07.
4. Disconnect the HCU electrical connector.

7. Detach the brake and fuel tubes from the

bulkhead.

5. CAUTION: Cap the brake tubes to

prevent fluid loss or dirt ingress.
NOTE: Make a note of the position of the brake
tubes to aid installation.
Disconnect the in-line brake tube unions.

8. Detach the clutch master cylinder hose

from the support bracket.

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206-09A-6 Anti-Lock Control 206-09A-6

REMOVAL AND INSTALLATION (Continued)

Installation
9. Remove the HCU support bracket retaining
nuts. 1. NOTE: Make sure the insulator pad is correctly
positioned on the bottom of the HCU before
installation.
To install, reverse the removal procedure.

10. Remove the HCU and support bracket

assembly.

11. NOTE: Make a note of the position of the

insulator pad to aid installation.
Detach the HCU from the support
bracket.
• Remove the HCU side clip.

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206-09B-1 Anti-Lock Control - Stability Assist 206-09B-1

SECTION 206-09B Anti-Lock Control - Stability

Assist
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 206-09-2

DESCRIPTION AND OPERATION

Anti-Lock Control - Stability Assist ..................................................................................... 206-09-3

DIAGNOSIS AND TESTING

Anti-Lock Control - Stability Assist ..................................................................................... 206-09-4

REMOVAL AND INSTALLATION

Steering Wheel Rotation Sensor........................................................................................ 206-09-5

Yaw Rate Sensor............................................................................................................... 206-09-7

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206-09B-2 Anti-Lock Control - Stability Assist 206-09B-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Super DOT 4 brake fluid ESD-M6C57-A

Torque Specifications
Description Nm lb-ft lb-in
Hydraulic control unit (HCU) support bracket re- 25 18 –
taining nuts
Brake tube to HCU union 20 15 –
Front wheel speed sensor retaining bolt 5 4 44
Yaw rate sensor 6 4 53

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206-09B-3 Anti-Lock Control - Stability Assist 206-09B-3

DESCRIPTION AND OPERATION

Anti-Lock Control - Stability Assist

DESCRIPTION AND OPERATION

The stability assist adds a further function known

as Electronic Stability Program (ESP) to the Anti-
lock Brakes (ABS) and Traction Control System
(TCS). Whereas the ABS/TCS function controls
wheel slip during braking and acceleration
(longitudinal dynamics), the active yaw control
stabilizes the vehicle about its vertical axis.
Sensors measure the position of the steering
wheel, the pressure in the brake master cylinder,
the yaw velocity (Yaw rate) and the acceleration
transverse to the vehicle (Lateral acceleration).
This makes it possible to compare the driver's
intention with the momentary vehicle behaviour
so that in the event of the vehicle becoming
unstable the stability assist system can initiate
the appropriate corrective action.
The stability assist recognizes critical driving
conditions, such as panic reactions in dangerous
situations and stabilizes the vehicle by
individually braking each wheel and engine
control intervention without the need to a actuate
the brake or the accelerator pedal.

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206-09B-4 Anti-Lock Control - Stability Assist 206-09B-4

DIAGNOSIS AND TESTING

Anti-Lock Control - Stability Assist

DIAGNOSIS AND TESTING

REFER to Section 206-09A / 206-09B.

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206-09B-5 Anti-Lock Control - Stability Assist 206-09B-5

REMOVAL AND INSTALLATION

Steering Wheel Rotation Sensor

REMOVAL AND INSTALLATION

Removal
2. WARNING: Make sure the steering
1. Remove the steering column. For wheel rotation sensor drive pins are
additional information, refer to Section correctly located in the sensor hub.
211-04. Failure to follow this instruction, may
result in personal injury.
2. Remove the steering wheel rotation sen-
sor. Check the steering wheel rotation sensor
drive pin to sensor hub for excessive free-
play.

Installation
3. WARNING: Do not use excessive force
1. WARNING: Make sure that the steering when installing the steering wheel
wheel rotation sensor drive pins are rotation sensor. Failure to follow this
not damaged, loose or worn. Failure to instruction may result in personal
follow this instruction, may result in injury.
personal injury.
WARNING: Do not use a damaged
Check the steering wheel rotation sensor steering wheel rotation sensor. Failure to
drive pins. follow this instruction may result in
personal injury.
Install the steering wheel rotation sensor.
• Tighten the screws in the sequence shown.

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206-09B-6 Anti-Lock Control - Stability Assist 206-09B-6

REMOVAL AND INSTALLATION (Continued)

4. WARNING: Make sure that the steering

wheel rotation sensor is correctly
fitted to the support bracket. Failure to
follow this instruction, may result in
personal injury.
Check the vertical alignment of the steer-
ing wheel rotation sensor.

5. Install the steering column. For additional

information, refer to Section 211-04.

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206-09B-7 Anti-Lock Control - Stability Assist 206-09B-7

REMOVAL AND INSTALLATION

Yaw Rate Sensor

Removal 4. Remove the insulation pad.

All vehicles
1. Disconnect the battery ground cable.
For additional information, refer to Section
414-01.
Vehicles with automatic transaxle
2. Remove the automatic transaxle selector
lever trim panel.

All vehicles
5. Remove the floor console side trim panels.
1. Remove the retaining screw.
2. Detach the retaining clips.

Vehicles with manual transaxle

3. Remove the gearshift lever boot.

6. Disconnect the yaw rate sensor electrical

connector.

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206-09B-8 Anti-Lock Control - Stability Assist 206-09B-8

REMOVAL AND INSTALLATION (Continued)

7. Remove the yaw rate sensor left-hand re- 10. Remove the yaw rate sensor.
taining nut. 1. Raise the yaw rate sensor off the locating
stud.
2. Rotate the yaw rate sensor.
3. Remove the yaw rate sensor.

Vehicles with manual transaxle

8. Disconnect the gear linkage and position
to one side.
1. Detach the gear linkage from the ball joint.
2. Rotate the linkage through 90°.
Installation
1. WARNING: Do not use a damaged yaw
rate sensor. Failure to follow this
instruction may result in personal
injury.
WARNING: Install the yaw rate sensor
with the direction arrow pointing towards
the front of the vehicle. Failure to follow
this instruction may result in personal
injury.
CAUTION: The yaw rate sensor will be
damaged if dropped.

All vehicles To install, reverse the removal procedure.

9. Remove the yaw rate sensor right-hand
retaining nut.

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211-00-1 Steering System - General Information 211-00-1

SECTION 211-00 Steering System - General

Information
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 211-00-2

DESCRIPTION AND OPERATION

Steering System ................................................................................................................ 211-00-3

DIAGNOSIS AND TESTING

Steering System ................................................................................................................ 211-00-8

Inspection and Verification ............................................................................................... 211-00-8
Symptom Chart ................................................................................................................ 211-00-8
Component Tests ............................................................................................................. 211-00-13

GENERAL PROCEDURES

Power Steering System Flushing — 1.8L/2.0L.............................................. (13 001 0) 211-00-14

Power Steering System Flushing — 2.5L ..................................................... (13 001 0) 211-00-17
Power Steering System Bleeding ................................................................. (13 416 1) 211-00-20
Power Steering System Filling ...................................................................... (13 002 0) 211-00-21

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211-00-2 Steering System - General Information 211-00-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Power Steering Fluid WSA-M2C195-A
Anti-seize Grease SAM 1C9107A

Steering Wheel Alignment

Degrees
Maximum allowable steering wheel mis-alignment +/-3

Steering Gear
mm
Steering gear rack travel 73.3

Turning Circle
Metres
Turning circle 11,1

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211-00-3 Steering System - General Information 211-00-3

DESCRIPTION AND OPERATION

Steering System
DESCRIPTION AND OPERATION

All vehicles

Item Part Description

Item Part Description Number
Number
3 Windshield wiper
1 Passive anti-theft system switch/washer switch
(PATS) transceiver
4 Turn signal lamp switch
2 Clockspring

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211-00-4 Steering System - General Information 211-00-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
5 Steering column upper 11 Steering gear to bulkhead
shroud seal
6 Driver air bag module 12 Steering column flexible
coupling
7 Steering wheel
13 Steering column
8 Ignition switch
14 Steering wheel rotation sen-
9 Steering column lower
sor
shroud
10 Audio control switch

Vehicles with 2.5L engine

Item Part Description

Item Part Description Number
Number
5 Steering gear to power
1 Power steering fluid reser- steering fluid cooler return
voir hose
2 Power steering pump to 6 Power steering fluid cooler
steering gear pressure line
7 Power steering pump
3 Steering gear
4 Tie-rod end

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211-00-5 Steering System - General Information 211-00-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
8 Power steering fluid reser- 9 Power steering pressure
voir to power steering pump (PSP) switch
hose

Vehicles with Diesel engine

Item Part Description

Item Part Description Number
Number
5 Steering gear
1 Power steering fluid reser-
voir 6 Tie-rod end

2 Power steering fluid reser- 7 Steering gear to power

voir to power steering pump steering fluid cooler return
hose hose

3 Power steering pump 8 Power steering fluid cooler

4 Power steering pump to 9 Power steering fluid cooler

steering gear pressure line to power steering fluid reser-
voir hose

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211-00-6 Steering System - General Information 211-00-6

DESCRIPTION AND OPERATION

Vehicles with 1.8L and 2.0L engine

Vehicles with 1.8L or 2.0L engine

Item Part Description The power steering pump has the fluid reservoir
Number mounted directly on the pump. The power
1 Power steering fluid reser- steering pump is mounted directly on the engine
voir without any intermediate bracket.
2 Power steering pressure Vehicles with diesel engine
(PSP) switch Have a power steering pump which is mounted
3 Power steering pump to directly on the water pump. This pump has been
steering gear pressure line designed as a tandem pump, one shaft drives
both the power steering pump and the water
4 Steering gear pump.
5 Tie-rod end Vehicles with 2.5L engine
6 Steering gear to fluid cooler The power steering pump, is the same as
return hose previous models fitted with 2.5L engine.
7 Power steering fluid cooler All vehicles
8 Power steering fluid reser- The steering column is adjustable for height and
voir to power steering pump reach as standard. Vehicles with Electronic
hose Stability Program (ESP), have a steering column
installed on which there is a steering wheel
9 Power steering pump rotation sensor. No repairs may be made to the
mechanical part of the steering column. The

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211-00-7 Steering System - General Information 211-00-7

DESCRIPTION AND OPERATION (Continued)

complete steering column must be changed if it is

damaged.

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211-00-8 Steering System - General Information 211-00-8

DIAGNOSIS AND TESTING

Steering System
DIAGNOSIS AND TESTING

Mechanical Electrical
– Incorrect tire – Power steering
pressure, loose pressure (PSP)
General Equipment
wheels switch
Spring scale – Loose tie-rod ends, – Wiring harness
inner ball joints – Circuit
– Loose strut and
Inspection and Verification spring assemblies
or ball joints
1. Verify the customer concern by driving the
vehicle. – Loose steering
column shaft
2. Visually inspect for obvious signs of
universal joints
mechanical or electrical damage.
– Loose pinch bolts
Visual Inspection Chart on steering column
shaft flexible
coupling
– Loose steering gear
assembly
– Incorrect accessory
drive belt tension
– Binding or
misaligned steering
column, pump,
steering gear
– Incorrect power
steering pump
– Incorrect fluid level
– Hose leak or line
restrictions
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.
Symptom Chart

Condition Possible Sources Action

• Condition where the vehicle • Incorrect tire size or pressure. • CHECK for correct tire sizes and
wanders side-to-side on the adjust tire pressures. REFER to
road, when it is driven straight Section 204-04.
ahead while the steering wheel
is held in a firm position.
• Vehicle is unevenly loaded or • ADJUST the load.
overloaded.

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211-00-9 Steering System - General Information 211-00-9

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Loose or worn tie-rods or tie-rod • INSTALL a new steering gear or
ends. tie-rod end as necessary.
REFER to Section 211-02 / 211-
03.
• Steering gear bolts loose or • TIGHTEN or INSTALL new
damaged. bolts.
• Loose or worn suspension ball • INSTALL a new suspension ball
joint(s). joint assembly. REFER to Sec-
tion 204-01.
• Steering column shaft flexible • TIGHTEN the pinion shaft bolts.
coupling to pinion shaft bolt • TIGHTEN the steering column
loose. shaft flexible coupling. REFER
to Section 211-04.
• Steering column shaft flexible • INSTALL a new steering column
coupling joints loose or worn. shaft flexible coupling. REFER
to Section 211-04.
• Incorrect toe adjustment. • ADJUST as necessary. REFER
to Section 204-00.
• Loose or worn rear suspension. • TIGHTEN loose, or INSTALL
new rear suspension compo-
nents. REFER to Section 204-
02.
• Vehicle tends to pull to one side • Incorrect tire pressure. • ADJUST the tire pressure.
when driven on a level surface. REFER to Section 204-04.
• Incorrect tire size or different • INSTALL a new tire as neces-
tire/tread type. sary. REFER to Section 204-04.
• Vehicle is unevenly or exces- • ADJUST the load evenly.
sively loaded.
• Incorrect toe adjustment. • ADJUST as necessary. REFER
to Section 204-00.
• Damaged front suspension • INSTALL new front suspension
components. component as necessary.
REFER to Section 204-01.
• Damaged rear suspension com- • INSTALL new rear suspension
ponents. components as necessary.
REFER to Section 204-02.
• Check front and rear brakes for • ADJUST as necessary. REFER
correct operation. to Section 206-00.
• Check for bent rear suspension • INSTALL new rear suspension
components and for damaged or components as necessary.
sagging coil springs in the front REFER to Section 204-00.
or the rear suspension. • INSTALL new rear suspension
components as necessary.
REFER to Section 204-02.

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211-00-10 Steering System - General Information 211-00-10

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Check the rear suspension for • INSTALL new rear suspension
loose or worn suspension com- components as necessary.
ponents or rear suspension REFER to Section 204-02.
bolts. • TIGHTEN all bolts. REFER to
Section 204-02.
• Feedback (whining or knocking • Steering gear input shaft cou- • INSTALL a new flexible coupling
noises in the steering gear) – pling joints. as necessary. REFER to Sec-
condition where roughness is tion 211-04.
felt in the steering wheel by the
driver when the vehicle is driven
over rough surfaces.
• Loose/worn tie-rods. • INSTALL a new steering gear as
necessary. REFER to Section
211-02.
• Steering gear bolts loose or • TIGHTEN or INSTALL new re-
damaged. taining bolts as necessary.
REFER to Section 211-02.
• Steering column shaft to flexible • TIGHTEN the bolt. REFER to
coupling pinch bolt loose. Section 211-04.
• Loose suspension bushing, • TIGHTEN or INSTALL new bolts
bolts or ball joints. or ball joint as necessary.
REFER to Section 204-01.
• Steering column shaft in bad • INSTALL a new steering column
condition. as necessary. REFER to Sec-
tion 211-04.
• Steering fails to return to center, • Incorrect tire pressure. • ADJUST tire pressures. REFER
following a turn, without manual to Section 204-04.
effort from the driver. In addition,
when the driver returns the
steering wheel to center, it may
have a sticky or catchy feel.
• Incorrect tire size or incorrect • INSTALL a new tire as neces-
type. sary. REFER to Section 204-04.
• Misaligned steering column tube • ALIGN the steering column
or column shroud rubbing steer- tube. REFER to Section 211-04.
ing wheel.
• Steering column shaft flexible • INSTALL a new flexible cou-
coupling, universal joints bind- pling. REFER to Section 211-04.
ing.
• Steering column shaft floor seal • INSTALL a new floor seal as
may be torn. necessary. REFER to Section
211-04.
• Binding or damage to tie-rods. • INSTALL a new steering gear as
necessary. REFER to Section
211-02.

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211-00-11 Steering System - General Information 211-00-11

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Damaged or worn front suspen- • INSTALL new front suspension
sion components. components as necessary.
REFER to Section 204-01.
• Incorrect toe adjustment. • ADJUST as necessary. REFER
to Section 204-00.
• Column bearing binding. • INSTALL a new steering col-
umn. REFER to Section 211-04.
• Fluid contamination. • FLUSH the power steering sys-
tem. REFER to Power Steering
System Flushing in this section.
• Heavy steering efforts while • Low power steering pump fluid. • FILL as necessary and check for
turning corners and during park- system leaks. REFER to Power
ing manoeuvres Steering System Filling in this
section.
• Incorrect accessory drive belt • CHECK the accessory drive belt
tension. tension. REFER to Section 303-
05.
• Hose or cooler external leak. • REPAIR or INSTALL a new
hose or cooler as necessary.
• Incorrect engine idle speed. • REFER to the Powertrain Con-
trol Emissions Diagnosis
(PC/ED) manual.
• Power steering pump pulley • INSTALL a new power steering
loose or warped. pump pulley. REFER to Section
211-02.
• Hose or cooler line restriction. • CLEAN or INSTALL a new hose
or cooler as necessary.
• Fluid contamination. • INSPECT system for foreign
objects, contamination. FLUSH
the power steering system.
REFER to Power Steering Sys-
tem Flushing in this section.
• Fluid aeration. • BLEED the system. REFER to
Power Steering System Bleed-
ing in this section.
• PSP switch open circuit. • TEST or INSTALL a new PSP
switch as necessary. REFER to
Section 303-14.
• Fluid leakage • Overfilled system. • CORRECT the fluid level as
necessary.
• Component leak. • LOCATE the suspect compo-
nent, and repair as necessary.
• Accessory drive belt squeal • Check accessory drive belt for • INSTALL a new accessory drive
(particularly at full steering correct tension or glazing. belt as necessary. REFER to
wheel travel and stand still park- Section 303-05.
ing)

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211-00-12 Steering System - General Information 211-00-12

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Chirp noise in steering pump • Loose or worn accessory drive • INSTALL a new accessory drive
belt. belt. REFER to Section 303-05.
• Power steering pump noisy • Low fluid level and possible • FILL to the specified level.
leak. PURGE the air from the system.
REFER to Power Steering Sys-
tem Purging in this section.
• Power steering pump. • CHECK for leaks. Repair as
necessary.
• INSTALL a new power steering
pump as necessary. REFER to
Section 211-02.
• Swish type noise • Fluid flow into the bypass valve • Normal noise.
of the pump valve housing with
fluid temperature below 54°C
(130°F).
• Whine type noise • Aerated fluid, air leak in system. • PURGE the air from the system.
REFER to Power Steering Sys-
tem Purging in this section.
• Check valve cover O-ring seal. • INSTALL a new power steering
pump as necessary. REFER to
Section 211-02.
• Power steering pump or reser- • Excessive fluid fill. • CORRECT the fluid level as
voir leaks necessary.
• Fluid cap missing, loose, dam- • INSTALL a new fluid cap or O-
aged or missing O-ring seal. ring seal, as necessary.
• Loose or damaged hose fittings. • INSTALL a new hose fitting as
necessary.
• Leakage at shaft seal: • INSTALL a new power steering
• Seal damage. pump. REFER to Section 211-
• Rotor shaft damage, such as 02.
grooving or scratches.
• Shaft bush or bushing worn.
• Inlet tube. • INSTALL a new power steering
pump. REFER to Section 211-
02.
• Housing porosity. • INSTALL a new power steering
pump. REFER to Section 211-
02.
• Loose outlet fitting nut or plug • TIGHTEN as necessary.
valve.
• Outlet fitting, nut or plug dam- • INSTALL a new power steering
aged. pump. REFER to Section 211-
02.

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211-00-13 Steering System - General Information 211-00-13

DIAGNOSIS AND TESTING

1. Park the vehicle on a dry, even surface and

apply the parking brake.
Component Tests 2. Start the engine and turn the steering wheel
from lock to lock several times until the
power steering fluid has reached a
Steering Linkage
temperature of 74°-79°C (165°-175°F).
CAUTION: Boots must be handled 3. With the steering in the straight ahead
carefully to avoid damage. Use new position, attach the spring scale to the
steering gear boot clamps when steering wheel rim. Measure the effort
installing boots. required to turn the steering wheel one
Inspect the boots for cuts, deterioration, twisting complete revolution in each direction,
or distortion. Check the steering gear boots to compare the result with the specifications
make sure they are tight. Install new boots or listed in this section.
clamps as necessary.
1. With the wheels in the straight ahead Tie-Rod Articulation Torques
position, gently turn the steering wheel to the 1. Detach both tie-rod ends from the wheel
left and right to check free play. knuckles. REFER to Section 211-03.
2. Free play should be between 0 and 6 mm (0 2. Attach the spring scale to a tie-rod end, pull
and 0.25 inch) at the steering wheel rim. If on the spring scale in line with the steering
the free play exceeds this limit, either the gear and measure the effort required to move
steering joints are worn or the backlash of the tie-rod.
the rack and pinion steering gear is 3. No free play is allowed. If the force required
excessive. to move the tie-rod is greater than listed in
3. Backlash cannot be adjusted, install a new the specifications in this section, install a new
steering gear. REFER to Section 211-02. steering gear. REFER to Section 211-02.
4. Grasp the steering wheel firmly and move it
up and down and to the left and right without
turning the wheel, to check for column
bearing wear, steering column shaft joint
play, steering wheel or steering column
looseness. REFER to Section 211-04.

Turning Effort Test

NOTE: Before carrying out this test, make sure
the toe adjustment and tire pressures are correct.
REFER to Section 204-00.

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211-00-14 Steering System - General Information 211-00-14

GENERAL PROCEDURES

Power Steering System Flushing — 1.8L/2.0L (13 001 0)

GENERAL PROCEDURES

3. Place the end of the power steering fluid

Special Tool(s) cooler return line into a suitable container.
4. Disconnect the crankshaft position (CKP)
Pliers, Valve Stem Oil seal sensor electrical connector.
303-508 (21-211)

Socket,Spark Plug
303-499 (21-202)

Name Specification
Power Steering Fluid WSA-M2C195-A
1. Remove the engine upper cover. 5. Using the special tool, disconnect the
spark plug wires from the spark plugs.

2. NOTE: Using a suitable blanking cap, cap the

power steering fluid reservoir. 6. Using the special tool, remove the spark
Disconnect the power steering fluid cooler plugs.
return line from the power steering fluid
reservoir.

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211-00-15 Steering System - General Information 211-00-15

GENERAL PROCEDURES (Continued)

7. NOTE: The vehicle must be raised with the 14. Remove the blanking cap from the power
wheels clear of the floor to allow the steering steering fluid reservoir and connect the
wheel to be rotated from lock to lock. power steering fluid cooler return line.
Raise and support the vehicle. For
additional information, refer to Section
100-02.
8. NOTE: When filling the power steering fluid
reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The fluid
should be poured slowly into the reservoir to
minimize the possibility of aeration. The fluid
level should be checked with the fluid cold.
Fill the power steering fluid reservoir to
the MAX mark with power steering fluid.
9. CAUTION: Do not continuously crank
the engine for more than 30 seconds,
as damage to the starter motor may 15. Using the special tool, install the spark
result. plugs.
NOTE: When flushing the power steering system,
make sure that the power steering fluid in the
reservoir does not fall below the minimum mark.
While cranking the engine for no more
than 30 seconds turn the steering wheel
from lock to lock.
• With the aid of another technician add 1
liter of clean power steering fluid.
10. Wait 60 seconds to allow the starter
motor to cool.
11. CAUTION: Do not continuously crank
the engine for more than 30 seconds,
as damage to the starter motor may
result. 16. Using the special tool, connect the spark
NOTE: When flushing the power steering system, plug wires to the spark plugs.
make sure that the power steering fluid in the
reservoir does not fall below the minimum mark.
While cranking the engine for a further 30
seconds turn the steering wheel from
lock to lock.
• With the aid of another technician add a
further 1 liter of clean power steering fluid.
12. When all the fluid has been used, turn the
ignition switch to the OFF position.
13. Lower the vehicle.

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211-00-16 Steering System - General Information 211-00-16

GENERAL PROCEDURES (Continued)

17. Connect the CKP sensor electrical con-
nector.

18. Install the engine upper cover.

19. NOTE: When filling the power steering fluid

reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The fluid
should be poured slowly into the reservoir to
minimize the possibility of aeration. The fluid
level should be checked with the fluid cold.
Fill the power steering fluid reservoir to
the MAX mark with power steering fluid.
20. Start the engine and slowly turn the
steering wheel from lock to lock.
21. Switch OFF the engine.
22. Check the fluid level. Fill up as
necessary.

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211-00-17 Steering System - General Information 211-00-17

GENERAL PROCEDURES

Power Steering System Flushing — 2.5L (13 001 0)

3. Using the special tool, remove the spark
plugs.
Special Tool(s)
Pliers,Spark Plug Connector
303-622 (21-226)

Socket,Spark Plug
303-499 (21-202)

Name Specification 4. Detach the power steering fluid reservoir

from the wheelhouse assembly.
Power Steering Fluid WSA-M2C195-A
1. Remove the engine upper cover.

5. NOTE: Using a suitable blanking cap, cap the

power steering fluid reservoir.
2. Using the special tool, disconnect the Disconnect the power steering fluid cooler
spark plug wires from the spark plugs. return line from the power steering fluid
reservoir.

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211-00-18 Steering System - General Information 211-00-18

GENERAL PROCEDURES (Continued)

6. Place the end of the power steering fluid 12. CAUTION: Do not continuously crank
cooler return line into a suitable container. the engine for more than 30 seconds,
7. Disconnect the crankshaft position (CKP) as damage to the starter motor may
sensor electrical connector. result.
NOTE: When flushing the power steering system,
make sure that the power steering fluid in the
reservoir does not fall below the minimum mark.
While cranking the engine for a further 30
seconds turn the steering wheel from
lock to lock.
• With the aid of another technician add a
further 1 liter of clean power steering fluid.
13. When all the fluid has been used, turn the
ignition switch to the OFF position.
14. Lower the vehicle.
15. Remove the blanking cap from the power
steering fluid reservoir and connect the
8. NOTE: The vehicle must be raised with the power steering fluid cooler return line.
wheels clear of the floor to allow the steering
wheel to be rotated from lock to lock.
Raise and support the vehicle. For
additional information, refer to Section
100-02.
9. NOTE: When filling the power steering fluid
reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The fluid
should be poured slowly into the reservoir to
minimize the possibility of aeration. The fluid
level should be checked with the fluid cold.
Fill the power steering fluid reservoir to
the MAX mark with power steering fluid.
10. CAUTION: Do not continuously crank 16. Attach the power steering fluid reservoir
the engine for more than 30 seconds, to the wheelhouse assembly.
as damage to the starter motor may
result.
NOTE: When flushing the power steering system,
make sure that the power steering fluid in the
reservoir does not fall below the minimum mark.
While cranking the engine for no more
than 30 seconds turn the steering wheel
from lock to lock.
• With the aid of another technician add 1
liter of clean power steering fluid.
11. Wait 60 seconds to allow the starter
motor to cool.

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211-00-19 Steering System - General Information 211-00-19

GENERAL PROCEDURES (Continued)

17. Using the special tool, install the spark 20. Install the engine upper cover.
plugs.

21. NOTE: When filling the power steering fluid

18. Using the special tool,connect the spark reservoir, make sure the power steering fluid
plug wires to the spark plugs. is clean and not agitated prior to use. The fluid
should be poured slowly into the reservoir to
minimize the possibility of aeration. The fluid
level should be checked with the fluid cold.
Fill the power steering fluid reservoir to
the MAX mark with power steering fluid.
22. Start the engine and slowly turn the
steering wheel from lock to lock.
23. Switch OFF the engine.
24. Check the fluid level. Fill up as
necessary.

19. Connect the CKP sensor electrical con-

nector.

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211-00-20 Steering System - General Information 211-00-20

GENERAL PROCEDURES

Power Steering System Bleeding (13 416 1)

5. NOTE: When bleeding the system the vacuum
will decrease. Maintain a sufficient vacuum of
51 kPa (15 in - Hg), using the hand
Special Tool(s) vacuum/pressure pump. If the vacuum
Adaptor, Power Steering decreases by more than 7 kPa (2 in - Hg) in 5
Bleeding minutes, the system should be checked for
leaks.
211 - 189 (13 - 016)
Using the special tools, bleed the system.
• Start the engine and slowly turn the
steering wheel from lock to lock once; then
Hand Vacuum/Pressure turn the steering wheel to the right, just off
Pump the stop.
416 - D001 (23 - 036A) • Switch OFF the engine and using the hand
vacuum/pressure pump apply a vacuum of
51 kPa (15 in - Hg). Maintain the vacuum
until the air is evacuated from the system
(minimum of five minutes).
Bleeding • Release the vacuum at the hand vacuum/
pressure pump.
1. NOTE: When filling the reservoir, make sure
the power steering fluid is clean and not • Repeat the bleed procedure, turning the
agitated prior to use. The fluid should be steering wheel to the left, just off the stop.
poured slowly into the reservoir to minimize
the possibility of aeration. The fluid level
should be checked with the fluid cold.
Fill the reservoir to the MAX mark.

6. Remove the hand vacuum/pressure pump

and stopper. Fill the reservoir if necessary.
7. Start the engine, turn the steering wheel
from lock to lock. If excessive noise is
apparent, repeat the bleed procedure.
2. NOTE: Make sure that the fluid in the reservoir
does not fall below the MIN mark, as air could 8. If the noise level is still unacceptable,
enter the system. leave the vehicle standing overnight then
repeat the bleed procedure.
Start the engine and slowly turn the
steering wheel from lock to lock.
3. Switch OFF the engine and examine the
hose connections, steering gear boots,
valve body and pump for external leaks.
4. Check the fluid level. Fill up as necessary.

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211-00-21 Steering System - General Information 211-00-21

GENERAL PROCEDURES

Power Steering System Filling (13 002 0)

2. Using the special tools, apply a vacuum of
84 - 101 kPa (25 - 30 in - Hg) for 30 sec-
onds.
Special Tool(s)
Adaptor, Power Steering
Bleeding
211 - 189 (13 - 016)

Hand Vacuum/Pressure
Pump
416 - D001 (23 - 036A)

Refill 3. Observe the vacuum gauge reading.

• If the vacuum decreases by more than 7
1. NOTE: When filling the reservoir, make sure
kPa (2 in - Hg) in 5 minutes, the system
the power steering fluid is clean and not
should be checked for leaks.
agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize 4. Remove the hand vacuum/pressure pump
the possibility of aeration. The fluid level and stopper. Fill the reservoir to the MAX
should be checked with the fluid cold. mark is necessary.
Fill the reservoir to the MAX mark.

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211-02-1 Power Steering 211-02-1

SECTION 211-02 Power Steering

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 211-02-2

DESCRIPTION AND OPERATION

Power Steering.................................................................................................................. 211-02-3

DIAGNOSIS AND TESTING

Power Steering.................................................................................................................. 211-02-6

REMOVAL AND INSTALLATION

Power Steering Pump — 1.8L/2.0L .............................................................. (13 434 0) 211-02-7

Power Steering Pump — 2.5L ...................................................................... (13 434 0) 211-02-11
Power Steering Pump Pulley — 1.8L/2.0L.................................................... (13 425 0) 211-02-15
Steering Gear ............................................................................................... (13 116 0) 211-02-16

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211-02-2 Power Steering 211-02-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Power Steering Fluid WSA-M2C195-A
Anti-seize grease SAM 1C 9107A

Torque Specifications
Description Nm lb-ft lb-in
Steering gear mounting bolts 130 96 -
Power steering line to steering gear screw 23 17 -
Front sub-frame retaining bolts 142 105 -
Roll restrictor retaining bolt 80 59 -
Steering column shaft to flexible coupling bolt 20 15 -
Flexible coupling to steering gear pinion bolt 25 18 -
Front sub-frame assembly rear retaining bolt sup- 10 7 -
port bracket bolts
Tie-rod end retaining nut 40 30 -
Power steering pump retaining bolts — vehicles 48 35 -
with 2.5L engine
Power steering pump plate retaining bolts — vehi- 25 18 -
cles with 2.5L engine
Power steering pump plate retaining nuts — vehi- 10 7 -
cles with 2.5L engine
Power steering pump pulley retaining bolts — ve- 25 18 -
hicles with 2.5L engine
Power steering line to power steering pump union 17 13 -
— vehicles with 2.5L engine
Engine front mounting retaining bolts — vehicles 83 61 -
with 2.5L engine
Power steering pump retaining bolts — vehicles 18 13 -
with 1.8L or 2.0L engine
Power steering line to power steering pump sup- 8 6 -
port bracket nut — vehicles with 1.8L or 2.0L en-
gine
Power steering line to power steering pump union 65 48 -
— vehicles with 1.8L or 2.0L engine
Power steering fluid reservoir retaining bolts — 9 7 -
vehicles with 1.8L or 2.0L engine
Power steering pump retaining bolts — vehicles 23 17 -
with diesel engine
Power steering pump pulley retaining bolts — ve- 10 7 -
hicles with diesel engine
Power steering line to power steering pump union 23 17 -
— vehicles with diesel engine
Exhaust pipe flexible coupling retaining bolts 46 34 -
Tie-rod end locknut 40 30 -
Tie-rod to steering gear 110 81 -

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211-02-3 Power Steering 211-02-3

DESCRIPTION AND OPERATION

Power Steering
DESCRIPTION AND OPERATION

Vehicles with 2.5L and 3.0L engine

Item Description Item Description

1 Power steering fluid reservoir 6 Power steering fluid cooler
2 Power steering pump to steering gear 7 Power steering pump
pressure line 8 Power steering fluid reservoir to power
3 Steering gear steering pump hose
4 Tie-rod end 9 Power steering pressure (PSP) switch
5 Steering gear to fluid cooler return hose

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211-02-4 Power Steering 211-02-4

DESCRIPTION AND OPERATION

Vehicles with diesel engine

Item Description Item Description

1 Power steering fluid reservoir 5 Steering gear
2 Power steering fluid reservoir to power 6 Tie-rod end
steering pump hose 7 Steering gear to fluid cooler return hose
3 Steering pump 8 Power steering fluid cooler
4 Power steering pump to steering gear 9 Power steering fluid cooler to power
pressure line steering fluid reservoir hose

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211-02-5 Power Steering 211-02-5

DESCRIPTION AND OPERATION

Vehicles with 1.8L and 2.0L engine

Item Description
1 Power steering fluid reservoir
2 Power steering pressure (PSP) switch
3 Power steering pump to steering gear
pressure line
4 Steering gear
5 Tie-rod end
6 Steering gear to fluid cooler return hose
7 Power steering fluid cooler
8 Power steering fluid reservoir to power
steering pump hose
9 Power steering pump

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211-02-6 Power Steering 211-02-6

DIAGNOSIS AND TESTING

Power Steering
DIAGNOSIS AND TESTING

REFER to Section 211-00.

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211-02-7 Power Steering 211-02-7

REMOVAL AND INSTALLATION

Power Steering Pump — 1.8L/2.0L (13 434 0)

REMOVAL AND INSTALLATION

3. Remove the engine wiring harness support

bracket.
Special Tool(s)
Expander, Teflon Seal
211-188 (13-015)

Remover, Power Steering

Pump Pulley
211-198 (13-021)

Installer, Camshaft Pulley

4. Disconnect the power steering hose from
303-458 (21-192) the power steering fluid reservoir.
• Allow the fluid to drain into a suitable con-
tainer.

Removal
1. Remove the accessory drive belt. For
additional information, refer to Section
303-05.
2. NOTE: When installing a new power steering
pump, a new power steering pump pulley must
be installed.
Using the special tool, remove the power
steering pump pulley.

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211-02-8 Power Steering 211-02-8

REMOVAL AND INSTALLATION (Continued)

5. NOTE: The power steering fluid reservoir
8. Remove the power steering pump.
contains a filter. If the power steering fluid is
contaminated the power steering fluid
reservoir must be renewed.
Remove the power steering fluid reservoir.
1. Remove the rear retaining stud.
2. Remove the front retaining bolts.
• Discard the O-ring seals.

Installation
1. NOTE: If installing a new power steering
pump, the unions supplied with the new pump
should be removed and retained for further
use.
6. Remove the power steering line support Install the power steering pump.
retaining nut.

7. Disconnect the power steering line from

the power steering pump.

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211-02-9 Power Steering 211-02-9

REMOVAL AND INSTALLATION (Continued)

2. Using the special tool, install a new O-ring 5. Install new O-ring seals to the power steer-
seal onto the power steering line to power ing fluid reservoir.
steering pump union.
1. Push the O-ring seal onto the special tool.
2. Locate the special tool onto the union and
install the O-ring seal.

6. Install the power steering fluid reservoir.

1. Install the front retaining bolts.
2. Install the rear retaining stud.

3. Connect the power steering line to the

power steering pump.

7. Connect the power steering hose to the

power steering fluid reservoir.

4. Install the power steering line support re-

taining nut.

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211-02-10 Power Steering 211-02-10

REMOVAL AND INSTALLATION (Continued)

8. Install the engine wiring harness support
bracket.

9. NOTE: When installing a new power steering

pump, install a new power steering pump
pulley.
Using the special tool, install the new
power steering pump pulley flush with the
end of the power steering pump shaft.

10. Install the accessory drive belt. For

additional information, refer to Section
303-05.
11. Fill and bleed the power steering system.
For additional information, refer to
Section 211-00.

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211-02-11 Power Steering 211-02-11

REMOVAL AND INSTALLATION

Power Steering Pump — 2.5L (13 434 0)

3. Detach the power steering fluid reservoir
from the wheelhouse and position to one
side.
Special Tool(s)
1. Disconnect the power steering hose from
Expander, Teflon Seal the power steering pump.
211-188 (13-015) 2. Remove the retaining bolt.
• Allow the fluid to drain into a suitable con-
tainer.

General Equipment
Trolley jack

Removal
1. Remove the accessory drive belt. For
additional information, refer to Section
303-05.
2. Disconnect the power steering line from
the power steering pump.
1. Disconnect the power steering line. 4. Detach the coolant expansion tank from
2. Remove the support bracket retaining bolt. the wheelhouse and position to one side.
• Allow the fluid to drain into a suitable con-
tainer.

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211-02-12 Power Steering 211-02-12

REMOVAL AND INSTALLATION (Continued)

5. Detach the spark plug leads from the en- 8. NOTE: Use a 8 mm Allen key to prevent the
gine front mount. power steering pump pulley from rotating.
Remove the power steering pump pulley.

6. Using a suitable trolley jack and wooden

block, support the engine.
9. Remove the power steering pump.
1. Remove the power steering pump bracket
retaining bolt.
2. Remove the retaining plate nuts.
3. Remove the retaining plate bolts.
4. Remove the power steering pump retaining
bolts.
5. Remove the retaining plate.
6. Remove the pump.

7. Remove the engine front mount.

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211-02-13 Power Steering 211-02-13

REMOVAL AND INSTALLATION (Continued)

10. NOTE: When installing a new power steering 2. Install the power steering pump.
pump the power steering hose and power
steering line unions should be removed.
Remove the power steering hose and
power steering line unions.
• Remove and discard the O-ring seals.

3. NOTE: Use a 8 mm Allen key to prevent the

power steering pump pulley from rotating.
Install the power steering pump pulley.

Installation
1. NOTE: When installing a new power steering
pump, install the power steering hose and
power steering line unions.
NOTE: Install new O-ring seals.
Install the power steering hose and power
steering line unions.

4. Install the accessory drive belt. For

additional information, refer to Section
303-05.
5. Install the engine front mount.

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211-02-14 Power Steering 211-02-14

REMOVAL AND INSTALLATION (Continued)

6. Attach the spark plug leads to the engine 9. Using the special tool, install a new O-ring
front mount. seal onto the power steering line to power
steering pump union.
1. Push the O-ring seal onto the special tool.
2. Locate the special tool onto the union and
install the O-ring seal.

7. Attach the coolant expansion tank to the

wheelhouse.

10. Connect the power steering line to the

power steering pump.
1. Connect the power steering line.
2. Install the support bracket retaining bolt.

8. Attach the power steering fluid reservoir to

the wheelhouse.
1. Install the retaining bolt.
2. Connect the power steering hose to the
power steering pump.

11. Fill and bleed the power steering system.

For additional information, refer to
Section 211-00.

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211-02-15 Power Steering 211-02-15

REMOVAL AND INSTALLATION

Power Steering Pump Pulley — 1.8L/2.0L (13 425 0)

Installation
Special Tool(s)
1. NOTE: Install the power steering pump pulley
Remover, Power Steering flush with the end of the power steering pump
Pump Pulley shaft.
211-198 (13-021)
Using the special tool, install the power
steering pump pulley.

Installer, Camshaft Pulley

303-458 (21-192)

Removal
1. Remove the accessory drive belt. For
additional information, refer to Section
303-05.
2. Using the special tool, remove the power
steering pump pulley. 2. Install the accessory drive belt. For
additional information, refer to Section
303-05.

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211-02-16 Power Steering 211-02-16

REMOVAL AND INSTALLATION

Steering Gear (13 116 0)

3. CAUTION: Protect the ball joint seals
using a soft cloth to prevent damage.
Special Tool(s) Using the special tool, detach the left-hand
Separator, Ball Joint and right-hand tie-rod end from the wheel
knuckle (left-hand side shown).
211-020 (13-006)
1. Release the tie-rod ends.
2. Remove the tie-rod end retaining nuts.
• Discard the nuts.

General Equipment
Transmission Jack

Name Specification
Anti-seize grease SAM-1C9107-A

Removal
All vehicles
1. Remove the steering column flexible
coupling. For additional information, refer 4. Remove the steering gear bulkhead floor
to Section 211-04. seal.
2. CAUTION: Leave the tie-rod end
retaining nuts in place to protect the
ball joint studs.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Loosen the left-hand and right-hand tie-rod
end retaining nut (left-hand side shown).

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211-02-17 Power Steering 211-02-17

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.5L engine 8. Remove the steering gear retaining bolts.
5. Detach the power steering lines from the
steering gear.

9. NOTE: Remove the steering gear through the

wheel arch.
Vehicles with 1.8L, 2.0L and diesel engine.
Remove the steering gear through the
6. Detach the power steering lines from the
wheel arch.
steering gear.

All vehicles
7. Detach the power steering lines from the Installation
steering gear valve body.
All vehicles
• Discard the retaining bolt.
1. Install the steering gear.
• Discard the O-ring seals.

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211-02-18 Power Steering 211-02-18

REMOVAL AND INSTALLATION (Continued)

2. WARNING: Install a new retaining bolt. Vehicles with 1.8L, 2.0L and diesel engine
Failure to follow this instruction may 4. Attach the power steering lines to the
result in personal injury. steering gear.
NOTE: Install new o-ring seals.
Attach the power steering lines to the
steering gear valve body.

All vehicles
5. Install the steering gear bulkhead floor
seal.

Vehicles with 2.5L engine

3. Attach the power steering lines to the
steering gear.

6. Install the steering column flexible

coupling. For additional information, refer
to Section 211-04.

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211-02-19 Power Steering 211-02-19

REMOVAL AND INSTALLATION (Continued)

7. WARNING: Install new tie-rod end

retaining nuts. Failure to follow this
instruction may result in personal
injury.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Attach the tie-rod end to the left-hand and
right-hand wheel knuckle (left-hand side
shown).

8. Fill and bleed the power steering system.

For additional information, refer to Section
211-00.
9. Adjust the front wheel alignment. For
additional information, refer to Section
204-00.
Vehicles with stability assist
10. WARNING: The electronic stability
program must be re-configured.
Failure to follow this instruction, may
result in personal injury.
Configure the electronic stability program
using WDS.

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211-03-1 Steering Linkage 211-03-1

SECTION 211-03 Steering Linkage

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 211-03-2

DESCRIPTION AND OPERATION

Steering Linkage ............................................................................................................... 211-03-3

DIAGNOSIS AND TESTING

Steering Linkage ............................................................................................................... 211-03-4

REMOVAL AND INSTALLATION

Tie-Rod ........................................................................................................ (13 263 0) 211-03-5

Tie-Rod End ................................................................................................. (13 273 0) 211-03-8
Steering Gear Boot....................................................................................... (13 134 0) 211-03-10

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211-03-2 Steering Linkage 211-03-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Tie-rod end retaining nut 40 30 -
Tie-rod end locknut 40 30 -
Tie-rod to steering gear 110 81 -

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211-03-3 Steering Linkage 211-03-3

DESCRIPTION AND OPERATION

Steering Linkage
DESCRIPTION AND OPERATION

Item Part Description

Number
1 - Steering gear
2 - Steering gear boot
3 - Tie-rod
4 - Tie-rod end locknut
5 - Tie-rod end
6 - Wheel knuckle
7 - Tie-rod end retaining nut

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211-03-4 Steering Linkage 211-03-4

DIAGNOSIS AND TESTING

Steering Linkage
DIAGNOSIS AND TESTING

REFER to Section 211-00.

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211-03-5 Steering Linkage 211-03-5

REMOVAL AND INSTALLATION

Tie-Rod (13 263 0)

REMOVAL AND INSTALLATION

3. NOTE: Make sure the tie-rod is clean before

removing the steering gear boot.
Special Tool(s) Remove the steering gear boot.
Socket, Tie-Rod End, 1. Detach the steering gear breather pipe
Steering Gear from the steering gear boot.
211-245 (13-025) 2. Remove the steering gear boot retaining
clamps.
• Discard the clamps.

General Equipment
Vice jaw protectors
Pincers

Name Specification
Grease ESB-M1C119-B

Removal
1. Remove the steering gear. For additional
information, refer to Section 211-02. 4. Rotate the steering gear pinion to expose
2. NOTE: Make a note of the number of turns the rack.
used to remove the tie-rod end.
Remove the tie-rod end and the tie-rod end
locknut.
1. Remove the tie-rod end.
2. Remove the tie-rod end locknut.

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211-03-6 Steering Linkage 211-03-6

REMOVAL AND INSTALLATION (Continued)

5. CAUTION: Do not clamp the steering 2. NOTE: Lubricate the steering gear boot.
rack on exposed hydraulic sealing Install the steering gear boot.
surfaces.
CAUTION: Make sure vise jaw protectors
are used.
CAUTION: Clamp the steering rack in
vise jaws. Do not clamp the steering gear
body.
Secure the steering gear in a vice and us-
ing a suitable pipe wrench, remove the tie-
rod.

3. NOTE: Make sure the steering gear breather

pipe connection is at the top.
NOTE: Install a new steering gear boot inner
clamp.
Using a suitable pair of pincers, install the
steering gear boot inner clamp.

Installation
1. Using the special tool, install the tie-rod.

4. Attach the steering gear breather pipe.

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211-03-7 Steering Linkage 211-03-7

REMOVAL AND INSTALLATION (Continued)

5. NOTE: Make sure the steering gear boot outer

clamp is located over the recess in the tie-rod.
NOTE: Install a new steering gear boot outer
clamp.
Using a suitable pair of pincers, install the
steering gear boot outer clamp.

6. NOTE: Install the tie-rod end using the same

number of turns used to remove it.
Install the tie-rod end and tie-rod end lock-
nut.

7. Install the steering gear. For additional

information, refer to Section 211-02.
8. Adjust the front wheel alignment. For
additional information, refer to Section
204-00.

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211-03-8 Steering Linkage 211-03-8

REMOVAL AND INSTALLATION

Tie-Rod End (13 273 0)

3. CAUTION: Protect the ball joint seal
using a soft cloth to prevent damage.
Special Tool(s) Using the special tool, detach the tie-rod
Separator, Ball Joint end from the wheel knuckle.
211-020 (13-006) 1. Release the tie-rod end.
2. Remove the tie-rod end retaining nut.
• Discard the retaining nut.

Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. CAUTION: Leave the tie-rod end
retaining nut in place to protect the
ball joint stud.
NOTE: Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Loosen the tie-rod end locknut and the tie- 4. NOTE: Make a note of the number of turns
rod end retaining nut. used to remove the tie-rod end.
1. Loosen the locknut. Remove the tie-rod end.
2. Loosen the retaining nut.

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211-03-9 Steering Linkage 211-03-9

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Install the tie-rod end using the same
number of turns used to remove it.
Install the tie-rod end.

2. WARNING: Install a new tie-rod end

retaining nut. Failure to follow this
instruction may result in personal
injury.
NOTE: Use a 5 mm Allen key to prevent the ball
joint from rotating.
Tighten the tie-rod end locknut and the tie-
rod end retaining nut.
1. Tighten the retaining nut.
2. Tighten the locknut.

3. Lower the vehicle.

4. Check the toe setting and adjust as
necessary. For additional information,
refer to Section 204-00.

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211-03-10 Steering Linkage 211-03-10

REMOVAL AND INSTALLATION

Steering Gear Boot (13 134 0)

All vehicles
4. Remove the tie-rod end locknut.
General Equipment
Pincers

Name Specification
Grease ESB-M1C119-B

Removal
All vehicles
1. Remove the tie-rod end. For additional
information, refer to Tie-Rod End in this
section.
5. NOTE: Make sure the tie-rod is clean before
Vehicles with diesel engine removing the steering gear boot.
2. Remove the engine undershield.
Remove the steering gear boot.
1. Detach the steering gear breather pipe
from the steering gear boot.
2. Remove the steering gear boot clamps.
• Discard the clamps.

3. Remove the splash shield (left-hand side

only).

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211-03-11 Steering Linkage 211-03-11

REMOVAL AND INSTALLATION (Continued)

Installation 3. Attach the steering gear breather pipe to

the steering gear boot.
All vehicles
1. NOTE: Lubricate the steering gear boot.
Install the steering gear boot.

4. NOTE: Make sure the steering gear boot outer

clamp is located over the recess in the tie-rod.
NOTE: Install a new steering gear boot outer
2. NOTE: Make sure the steering gear breather clamp.
pipe connection is at the top. Using a suitable pair of pincers, install the
NOTE: Install a new steering gear boot inner steering gear boot outer clamp.
clamp.
Using a suitable pair of pincers, install the
new steering gear boot inner clamp.

5. Install the tie-rod end locknut.

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211-03-12 Steering Linkage 211-03-12

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine
6. Install the splash shield (left-hand side
only).

7. Install the engine undershield.

All vehicles
8. Install the tie-rod end. For additional
information, refer to Tie-Rod End in this
section.

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211-04-1 Steering Column 211-04-1

SECTION 211-04 Steering Column

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 211-04-2

DESCRIPTION AND OPERATION

Steering Column................................................................................................................ 211-04-3

DIAGNOSIS AND TESTING

Steering Column................................................................................................................ 211-04-5

REMOVAL AND INSTALLATION

Steering Wheel............................................................................................. (13 524 0) 211-04-6

Ignition Switch Lock Cylinder ............................................................................................. 211-04-7
Steering Column........................................................................................... (13 542 0) 211-04-9
Steering Column Flexible Coupling............................................................... (13 566 0) 211-04-15

DISASSEMBLY AND ASSEMBLY

Steering Column........................................................................................... (13 543 4) 211-04-24

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211-04-2 Steering Column 211-04-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Steering wheel retaining bolt 45 33 -
Steering column retaining bolts 24 18 -
Steering wheel rotation sensor retaining screws 1 - 9
Driver air bag module retaining screws 5 - 44
Steering column shaft to flexible coupling bolt 20 15 -
Flexible coupling to steering gear pinion pinch bolt 25 18 -

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211-04-3 Steering Column 211-04-3

DESCRIPTION AND OPERATION

Steering Column
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 – Windshield wiper/washer
1 – Passive anti–theft system switch
(PATS) transceiver
4 – Turn signal lamp switch
2 – Clockspring

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211-04-4 Steering Column 211-04-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
5 – Steering column upper
shroud
6 – Driver air bag module
7 – Steering wheel
8 – Ignition switch
9 – Steering column lower
shroud
10 – Audio control switch
11 – Steering gear to bulkhead
seal
12 – Steering column flexible
coupling
13 – Steering column
14 – Steering wheel rotation sen-
sor

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211-04-5 Steering Column 211-04-5

DIAGNOSIS AND TESTING

Steering Column
DIAGNOSIS AND TESTING

REFER to Section 211-00.

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211-04-6 Steering Column 211-04-6

REMOVAL AND INSTALLATION

Steering Wheel (13 524 0)

REMOVAL AND INSTALLATION

Removal
1. Remove the driver air bag module. For
additional information, refer to Section
501-20A / 501-20B.
2. NOTE: Make sure the road wheels are in the
straight ahead position.
Centralize the steering and lock it in posi-
tion.

3. Remove the steering wheel.

Installation
1. To install, reverse the removal procedure.

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211-04-7 Steering Column 211-04-7

REMOVAL AND INSTALLATION

Ignition Switch Lock Cylinder

Removal 4. Remove the audio control switch (if

equipped).
All vehicles
1. Disconnect the battery ground cable. For • Disconnect the electrical connector.
additional information, refer to Section
414-01.
2. Remove the instrument panel lower panel.
1. Remove the retaining screws.
2. Release the retaining clips.

5. Detach the steering column upper shroud

from the steering column lower shroud.
1. Using a thin bladed screwdriver, release
the two clips (one each side).
2. Detach the shroud.
3. Detach the audio control switch from the
steering column lower shroud (if
equipped).
• Using a thin bladed screwdriver, release
the locking tang.

6. Remove the steering column lower shroud.

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211-04-8 Steering Column 211-04-8

REMOVAL AND INSTALLATION (Continued)

Right-hand drive vehicles
7. Remove the passive anti-theft (PATS)
9. Remove the ignition lock cylinder (steering
transceiver (steering wheel shown re-
wheel shown removed for clarity).
moved for clarity).
1. Insert and turn the ignition key to position I.
2. Using a thin bladed screwdriver, depress
the detent.

Left-hand drive vehicles

8. Remove the ignition lock cylinder (steering
wheel shown removed for clarity).
1. Insert and turn the ignition key to position I.
2. Using a thin bladed screwdriver, depress Installation
the detent.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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211-04-9 Steering Column 211-04-9

REMOVAL AND INSTALLATION

Steering Column (13 542 0)

the instrument panel lower panel (if
equipped).
• Remove the instrument panel lower panel.
Name Specification
Silicon Grease
YS5J-M1C239-AA

Removal
All vehicles
1. Remove the driver air bag module. For
additional information, refer to Section
501-20A / 501-20B.
2. NOTE: Make sure the road wheels are in the
straight ahead position.
Centralize the steering and lock it in posi-
tion. 5. Remove the insulation pad (if equipped).

3. Detach the instrument panel lower panel 6. Detach the audio control switch from the
from the instrument panel. steering column lower shroud (if
equipped).
1. Remove the retaining screws.
• Using a thin bladed screwdriver, release
2. Detach the retaining clips.
the locking tang.

4. Detach the electronic automated

temperature control (EATC) sensor from
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211-04-10 Steering Column 211-04-10

REMOVAL AND INSTALLATION (Continued)

7. Remove the audio control switch (if 10. Disconnect the ignition switch and turn
equipped). signal electrical connectors.
• Disconnect the electrical connector.

11. Disconnect the passive anti-theft system

8. Detach the steering column upper shroud (PATS) transceiver, windshield
from the steering column lower shroud. wiper/washer switch and clockspring
electrical connectors.
1. Using a thin bladed screwdriver, release
the two retaining clips (one each side).
2. Detach the shroud.

12. NOTE: Note the routing of the clockspring

wiring harness, to aid installation.
9. Remove the steering column lower shroud. Detach the spreader plate from the steer-
ing column.

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211-04-11 Steering Column 211-04-11

REMOVAL AND INSTALLATION (Continued)

Vehicles with stability assist Installation

13. Disconnect the steering wheel rotation
sensor electrical connector. All vehicles
1. WARNING: Install new steering column
retaining bolts. Failure to follow this
instruction may result in personal
injury.
WARNING: Make sure the steering
column adjustment lever is in the locked
position. Failure to follow this instruction
may result in personal injury.
Install the steering column.

All vehicles
14. Detach the steering column shaft from
the steering column flexible coupling.
1. Remove and discard the retaining bolt.
2. Rotate the clamp plate.

2. Apply silicon grease to the steering shaft

compensator and fully extend and retract
the steering column several times.

15. Remove the steering column.

• Discard the retaining bolts.

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211-04-12 Steering Column 211-04-12

REMOVAL AND INSTALLATION (Continued)

3. Using a pre-prepared spacer, set the steer- 6. Fully tighten the steering column shaft to
ing shaft compensator to 70 mm. the steering column flexible coupling re-
taining bolt.

4. WARNING: Install a new steering

column to steering column flexible Vehicles with stability assist
coupling retaining bolt. Failure to 7. Connect the steering wheel rotation sen-
follow this instruction may result in sor electrical connector.
personal injury.
NOTE: Leave the spacer in position.
NOTE: Do not fully tighten the retaining bolt at
this stage.
Attach the steering column shaft to the
steering column flexible coupling.
1. Rotate the clamp plate.
2. Install the retaining bolt.

5. Check the steering shaft compensator and

adjust if necessary.

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211-04-13 Steering Column 211-04-13

REMOVAL AND INSTALLATION (Continued)

All vehicles 10. Connect the ignition switch and turn sig-
nal electrical connectors.
8. CAUTION: Make sure that the
clockspring wiring harness is routed
down the spreader plate depression
and, following the installation of the
spreader plate, that the clockspring
electrical connector is fully
connected.
Attach the spreader plate to the steering
column.

11. Install the steering column lower shroud.

9. Connect the passive anti-theft system

(PATS) transceiver, windshield
wiper/washer switch and clockspring elec-
trical connectors.

12. Attach the steering column upper shroud

to the steering column lower shroud.

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211-04-14 Steering Column 211-04-14

REMOVAL AND INSTALLATION (Continued)

13. Install the audio control switch (if 16. Attach the instrument panel lower panel
equipped). to the instrument panel.
1. Connect the electrical connector. 1. Attach the retaining clips.
2. Install the audio control switch 2. Install the retaining screws.

14. Install the insulation pad (if equipped). 17. Install the driver air bag module. For
additional information, refer to Section
501-20A / 501-20B.
18. Initialize the door window motors. For
additional information, refer to Section
501-11.
Vehicles with stability assist
19. WARNING: The steering wheel
rotation sensor must be re-configured
following installation. Failure to follow
this instruction may result in personal
injury
Configure the steering wheel rotation
sensor using WDS.
15. Attach the EATC sensor to the instrument
panel lower panel (if equipped).

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211-04-15 Steering Column 211-04-15

REMOVAL AND INSTALLATION

Steering Column Flexible Coupling (13 566 0)

2. Detach the steering column shaft from the
steering column flexible coupling.
Special Tool(s) 1. Remove the retaining bolt.
2. Rotate the clamp plate.
Alignment Pins, Subframe
• Discard the retaining bolt.
205-316 (15-097A)

General Equipment
Transmission jack
Wooden block

Name Specification
Silicon Grease YS5J-M1C239-AA

3. Using suitable pins, support the radiator

Removal on both sides.
All vehicles
1. NOTE: Make sure the road wheels are in the
straight ahead position.
Centralize the steering and lock it in posi-
tion.

4. Raise and support the vehicle. For

additional information, refer to Section
100-02.
5. Remove the splash shield.

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211-04-16 Steering Column 211-04-16

REMOVAL AND INSTALLATION (Continued)

11. Remove the exhaust heat shield support
Vehicles with diesel engine bracket.
6. Remove the engine undershield.

All vehicles
7. Remove the left-hand splash shield.
12. Remove the engine rear support insula-
tor.

Vehicles with 1.8L, 2.0L or diesel engine

8. Remove the exhaust flexible pipe. For
13. Remove the radiator support bracket re-
additional information, refer to Section
taining bolts on both sides.
309-00.
Vehicles with 2.5L engine
9. Remove the dual converter Y-pipe. For
additional information, refer to Section
309-00.
Vehicles with 3.0L engine
10. Remove the exhaust flexible pipes. For
additional information, refer to Section
309-00.

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211-04-17 Steering Column 211-04-17

REMOVAL AND INSTALLATION (Continued)

14. Remove the coolant hose support 17. Detach the catalyst monitor sensor wiring
bracket. harness from the subframe.

15. NOTE: Use a 5 mm Allen key to prevent the 18. Detach the radiator cooling fan wiring
ball joint stud from rotating. harness from the subframe.
Detach the stabilizer bar connecting link
from the suspension strut on both sides.

Vehicles with xenon headlamps

19. Detach the headlamp leveling sensor wir-
ing harness from the subframe.
16. Disconnect the catalyst monitor sensor
electrical connector.

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211-04-18 Steering Column 211-04-18

REMOVAL AND INSTALLATION (Continued)

All vehicles 23. CAUTION: Lower the subframe

20. Using a suitable transmission jack and uniformly to prevent the lower arm
wooden blocks support the subframe. hydro-bushings from damage.
Using the transmission jack, lower the
subframe approximately 150 mm.

21. Remove the subframe rear retaining bolts

and the subframe rear bracket retaining
bolts on both sides.
24. Remove the steering column flexible
coupling.
• Discard the retaining bolt.

22. Remove the subframe front retaining

bolts on both sides.

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211-04-19 Steering Column 211-04-19

REMOVAL AND INSTALLATION (Continued)

Installation All vehicles

3. Attach the radiator cooling fan wiring har-
All vehicles ness to the subframe.
1. WARNING: Make sure the steering
column flexible coupling is located on
the steering gear pinion shaft
correctly. Failure to follow this
instruction may result in personal
injury.
WARNING: Install a new steering column
flexible coupling retaining bolt. Failure to
follow this instruction may result in
personal injury.
Install the steering column flexible cou-
pling.

4. Attach the catalyst monitor sensor wiring

harness to the subframe.

Vehicles with xenon headlamps

2. Attach the headlamp leveling sensor wir-
ing harness to the subframe.
5. Connect the catalyst monitor sensor elec-
trical connector.

6. Using the special tool and a suitable

washer, align the subframe.
1. Insert the washer, with inside diameter 22
mm, outside diameter 44 mm and height 5

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211-04-20 Steering Column 211-04-20

REMOVAL AND INSTALLATION (Continued)

mm, into the subframe above the lower
alignment hole.
8. CAUTION: While tightening the
2. Insert the alignment pins through the
subframe retaining bolts, make sure
subframe and the washer.
the subframe does not move.
3. Slide the locking plate on top of the washer
and into the groove of the tool and tighten Install the subframe front retaining bolts
the alignment pin sleeve. on both sides.
• Lower and remove the transmission jack.

7. CAUTION: While tightening the

subframe retaining bolts, make sure 9. Remove the special tools.
the subframe does not move. 10. Install the engine rear support insulator.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

Vehicles with 3.0L engine

11. Install the exhaust heat shield support
bracket.

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211-04-21 Steering Column 211-04-21

REMOVAL AND INSTALLATION (Continued)

17. Install the radiator support brackets on

12. Install the exhaust flexible pipes. For
both sides.
additional information, refer to Section
309-00.
Vehicles with 1.8L, 2.0L or diesel engine
13. Install the exhaust flexible pipe. For
additional information, refer to Section
309-00.
Vehicles with 2.5L engine
14. Install the dual converter Y-pipe. For
additional information, refer to Section
309-00.
Vehicles with diesel engine
15. Install the left-hand splash shield.

18. Install the coolant hose support bracket.

All vehicles
16. NOTE: Use a 5 mm Allen key to prevent the
ball joint stud from rotating.
Attach the stabilizer bar connecting link 19. Install the splash shield.
to the suspension strut on both sides.

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211-04-22 Steering Column 211-04-22

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine 24. Using a pre-prepared spacer, set the
20. Install the engine undershield. steering shaft compensator to 70mm.

All vehicles 25. WARNING: Install a new steering

21. Lower the vehicle. column to steering column flexible
22. Remove the radiator support pins. coupling bolt. Failure to follow this
instruction may result in personal
injury.
NOTE: Leave the spacer in position.
NOTE: Do not fully tighten the retaining bolt at
this stage.
Attach the steering column shaft to the
steering column flexible coupling.
1. Rotate the clamp plate.
2. Install the retaining bolt.

23. Apply silicon grease to the steering shaft

compensator and fully extend and retract
the steering column several times.

26. Check the steering shaft compensator

and adjust if necessary.

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211-04-23 Steering Column 211-04-23

REMOVAL AND INSTALLATION (Continued)

27. Fully tighten the steering column shaft to

the steering column flexible coupling re-
taining bolt.

Vehicles with stability assist

28. WARNING: The electronic stability
program must be re-configured.
Failure to follow this instruction may
result in personal injury.
Configure the electronic stability program
using WDS.

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211-04-24 Steering Column 211-04-24

DISASSEMBLY AND ASSEMBLY

Steering Column (13 543 4)

DISASSEMBLY AND ASSEMBLY

Disassembly 3. Remove the passive anti-theft system

(PATS) transceiver.
All vehicles
1. Remove the steering wheel.

4. Remove the ignition switch.

• Release the locking tangs.
2. CAUTION: Make sure the clockspring
is not allowed to rotate. Secure in the
central position with a piece of
suitable tape.
Remove the steering column multifunction
switches and clockspring.
• Using a thin bladed screwdriver, release
the two clips (one each side).

Left-hand drive vehicles

5. Remove the ignition lock cylinder.
1. Insert and turn the ignition key to position I.
2. Using a thin bladed screwdriver, depress
the detent.

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211-04-25 Steering Column 211-04-25

DISASSEMBLY AND ASSEMBLY (Continued)

Assembly
Right-hand drive vehicles
6. Remove the ignition lock cylinder. Left-hand drive vehicles
1. Insert and turn the ignition key to position I. 1. Install the ignition lock cylinder.
2. Using a thin bladed screwdriver, depress
the detent.

Right-hand drive vehicles

2. Install the ignition lock cylinder.
Vehicles with stability assist
7. Remove the steering wheel rotation sen-
sor.

All vehicles
3. Install the ignition switch.

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211-04-26 Steering Column 211-04-26

DISASSEMBLY AND ASSEMBLY (Continued)

4. Install the PATS transceiver.

7. WARNING: Do not use excessive force
when installing the steering wheel
rotation sensor. Sensors that are
damaged must not be used. Failure to
follow this instruction may result in
personal injury.
WARNING: Make sure that the steering
wheel rotation sensor drive pin is
correctly located in the sensor hub.
Failure to follow this instruction, may
result in personal injury.
WARNING: Make sure that there is no
freeplay between the sensor hub and
drive pin. Failure to follow this
5. Install the steering column multifunction
instruction may result in personal injury.
switches and clockspring.
Make sure the steering wheel rotation
drive pin to sensor hub is a sliding fit.

Vehicles with stability assist

6. WARNING: Make sure that the steering 8. Install the steering wheel rotation sensor.
wheel rotation sensor drive pins are
• Tighten the screws in the sequence shown.
not damaged loose or worn. Failure to
follow this instruction, may result in
personal injury.
Check the steering wheel rotation sensor
drive pins for damage.

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211-04-27 Steering Column 211-04-27

DISASSEMBLY AND ASSEMBLY (Continued)

9. WARNING: Make sure that the steering

wheel rotation sensor is correctly
fitted. Failure to follow this
instruction, may result in personal
injury.
Check the vertical alignment of the steer-
ing wheel rotation sensor to the support
bracket.

All vehicles
10. Remove the tape from the clockspring.
11. Install the steering wheel.

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 Group

SECTION TITLE PAGE

Engine
Engine System - General Information.................................................................................... 303-00-1
Engine................................................................................................................................... 303-01A-1
Engine................................................................................................................................... 303-01B-1
Engine Cooling ...................................................................................................................... 303-03-1
Fuel Charging and Controls................................................................................................... 303-04A-1
Fuel Charging and Controls................................................................................................... 303-04B-1
Accessory Drive .................................................................................................................... 303-05-1
Starting System ..................................................................................................................... 303-06-1
Engine Ignition ...................................................................................................................... 303-07A-1
Engine Ignition ...................................................................................................................... 303-07B-1
Engine Emission Control ....................................................................................................... 303-08-1
Intake Air Distribution and Filtering ........................................................................................ 303-12-1
Evaporative Emissions .......................................................................................................... 303-13-1
Electronic Engine Controls .................................................................................................... 303-14-1
Automatic Transmission/Transaxle
Automatic Transmission/Transaxle........................................................................................ 307-01A-1
Automatic Transmission/Transaxle........................................................................................ 307-01B-1
Transmission/Transaxle Cooling ........................................................................................... 307-02A-1
Transmission/Transaxle Cooling ........................................................................................... 307-02B-1
Automatic Transmission/Transaxle External Controls............................................................ 307-05A-1
Automatic Transmission/Transaxle External Controls............................................................ 307-05B-1
Exhaust System
Exhaust System .................................................................................................................... 309-00-1
Fuel System
Fuel System - General Information ........................................................................................ 310-00-1
Fuel Tank and Lines.............................................................................................................. 310-01-1
Acceleration Control .............................................................................................................. 310-02-1
Speed Control ....................................................................................................................... 310-03-1

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303-00-1 Engine System - General Information 303-00-1

SECTION 303-00 Engine System - General

Information
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Engine ............................................................................................................................... 303-00-2

Engine - Oil Leaks ............................................................................................................ 303-00-6
Ultraviolet (UV) Testing .................................................................................................... 303-00-6
Measure the compression pressure (21 111 0)................................................................. 303-00-6
Measure the compression (Engine - 1.8L and 2.0L) ......................................................... 303-00-7
Measure the compression (Engine - 2.5L and 3.0L) ......................................................... 303-00-8
Measure the compression (Engine - 2.0L Diesel) ............................................................. 303-00-10
Oil Pressure - Measure (21 113 0).................................................................................... 303-00-12
Measure the oil pressure (Engine - 1.8L and 2.0L) ........................................................... 303-00-12
Measure the oil pressure (Engine - 2.5L and 3.0L) ........................................................... 303-00-14
Measure the oil pressure (Engine - 2.0L Diesel) ............................................................... 303-00-15
Valve train analysis - static (engine off) ............................................................................ 303-00-17

GENERAL PROCEDURES

Camshaft Bearing Journal Diameter .................................................................................. 303-00-18

Camshaft Bearing Journal Clearance ................................................................................ 303-00-19
Camshaft End Play............................................................................................................ 303-00-20
Camshaft Surface Inspection............................................................................................. 303-00-21
Camshaft Lobe Lift ............................................................................................................ 303-00-22
Crankshaft Main Bearing Journal Clearance...................................................................... 303-00-23
Crankshaft Main Bearing Journal Diameter ....................................................................... 303-00-24
Crankshaft End Play.......................................................................................................... 303-00-25
Cylinder Bore Taper .......................................................................................................... 303-00-26
Piston Inspection ............................................................................................................... 303-00-27
Piston Pin to Bore Diameter .............................................................................................. 303-00-28
Piston Diameter................................................................................................................. 303-00-29
Piston Ring End Gap ......................................................................................................... 303-00-30
Piston Ring-to-Groove Clearance ...................................................................................... 303-00-31
Piston Pin Diameter........................................................................................................... 303-00-32
Connecting Rod Large End Bore ....................................................................................... 303-00-33
Valve Stem Diameter......................................................................................................... 303-00-34
Valve Seat Inspection........................................................................................................ 303-00-35
Cylinder Head Distortion.................................................................................................... 303-00-36
Cylinder Block Distortion.................................................................................................... 303-00-37
Exhaust Manifold Cleaning and Inspection ........................................................................ 303-00-38
Bearing Inspection............................................................................................................. 303-00-39

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303-00-2 Engine System - General Information 303-00-2

DIAGNOSIS AND TESTING

Engine
DIAGNOSIS AND TESTING

1. Verify the customer concern by operating the (if possible) before proceeding to the next
system step.
2. Visually inspect for obvious signs of 4. If the concern is not visually evident, verify
mechanical or electrical damage. the symptom and refer to the Symptom
Chart.
Visual Inspection Chart
Mechanical Electrical
–Coolant leaks – Fuse(s)
–Oil leaks – Loose or corroded
–Fuel system leaks connector(s)
–Visibly damaged or – Control module
worn parts – Damaged or worn
– Loose or missing switch(es)
nuts or bolts
3. If an obvious cause for an observed or
reported concern is found, correct the cause
Condition Possible Sources Action
• Loss of oil • Oil leaks on components that • Look for evidence of oil leaks on
are either coated in oil or have components. Use an ultraviolet
always oil leaks on ancillary (UV) leak tester if oil leak is not
components. evident. Install new gaskets or
components as required.
• Internal or external leak at the • Check the coolant expansion
oil cooler. tank for oil film on the coolant
surface. Install a new oil cooler
or oil cooler gasket.
• Leak at the crankshaft oil seal or • Install a new oil seal.
incorrect front cover alignment. • Align the front cover.
• Leaks from oil carrying compo- • Locate cracks in oil-carrying
nents or basic engine. components of the basic engine
by means of a UV leak test, and
renew the relevant components
or seals.
• Oil consumption • Use of the wrong type of engine • Determine the last type of en-
oil. gine oil used (refer of the latest
invoice of oil receipt) and com-
pare with the specification.
Change the engine oil.

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303-00-3 Engine System - General Information 303-00-3

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Faulty positive crankcase • Check if the crankcase ventila-
ventilation system. tion system is operating cor-
• Hoses or ventilation or breather rectly and repair as necessary.
valves are blocked. This causes REFER to Section 303-08B.
excessive pressure in the
crankcase which causes more
oil to enter the combustion
chamber.
• Crankcase ventilation oil
separator is faulty and engine oil
can enter the combustion
chamber through the intake
manifold.
• Turbocharger seals (only diesel • Install a new turbocharger.
engines). REFER to Section 303-04A /
303-04B.
• Damaged gaskets or mating • Check the gaskets and mating
surfaces. surfaces for damage.
• Cylinder head gasket is • Remove the cylinder head.
damaged or mating face are Check the mating faces, cylinder
warped. head gaskets and the evenness
• Valve stem oil seals are worn of the cylinder head and engine
and engine oil can enter the block mating faces.
combustion chamber between • Install new valve stem oil seals.
the valve stem and the valve Engine - 1.8L and 2.0L - REFER
stem guide. to Section 303-01A / 303-01B.
Engine - 2.5L - Engine - 2.0L
Diesel - Engine - 3.0L -
• Piston ring or cylinder liner • Install new components as nec-
wear. essary.
• Damaged cylinder liners or • Check the running surfaces and
excessive clearance of engine clearances of the individual
components. engine components, and renew
• Pistons if necessary. Renew the cylinder
• Piston rings (clearance in block if necessary.
groove and end gap) • Pistons
• Cylinder liners • Piston rings
• Cylinder liners
• Coolant consumption • Cooling system components. • REFER to Section 303-03.
• Exhaust gas recirculation (EGR) • Install a new EGR cooler.
cooler (only diesel engine).
• Oil cooler. • Install a new oil cooler.
• Damaged gaskets or warped • Check the cylinder head gasket
mating faces. for damage. Check the cylinder
head for flatness.
• Cracks or fractures in engine • Determine the damaged engine
components surrounded by component and install a new
coolant, such as cylinder liners component.
and cylinder head combustion
chamber.

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303-00-4 Engine System - General Information 303-00-4

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Engine will not crank • Battery or cables. • Check the battery, bracket and
cables. REFER to Section 414-
01.
• Starter motor or cables. • Check the starting system.
REFER to Section 303-06.
• Engine cranks but will not start • Fuel tank is empty. • Check the fuel level.
• Water in fuel (only diesel en- • Drain the water from the fuel
gine). system. REFER to Section 310-
00.
• Fuel filter blocked. • Install a new fuel filter. REFER
to Section 310-01.
• Engine intake air system. • Check the intake air system.
REFER to Section 303-12.
• Glow plug faulty. • Check the glow plugs. Install
new glow plugs as necessary.
REFER to Section 303-07A /
303-07B.
• Engine management system. • Check the engine management
system. REFER to Section 303-
14.
• Ignition system (petrol engines • Check the ignition system. En-
only). gine - 1.8L and 2.0L - REFER to
Section 303-07A / 303-07B.
Engine 2.5L and 3.0L -
• Incorrect valve timing. • Check and adjust the valve tim-
ing. Engine - 1.8L and 2.0L -
REFER to Section 303-01A /
303-01B. Engine - 2.5L - En-
gine - 2.0L Diesel - Engine 3.0L
-
• Broken or damaged timing chain • Check the timing chain and
or sprocket. sprockets. Install new compo-
nents as necessary. Engine -
1.8L and 2.0L - REFER to Sec-
tion 303-01A / 303-01B. Engine
- 2.5L - Engine - 2.0L Diesel -
Engine 3.0L -
• Very poor power output or fuel • Fuel system. • Check the fuel system. Engine -
consumption too high or engine 1.8L and 2.0L - REFER to Sec-
running rough tion 303-04A / 303-04B. Engine
- 2.5L and 3.0L - Engine - 2.0L
Diesel -
• Engine intake air system. • Check the intake air system.
REFER to Section 303-12.
• Exhaust system blocked. • Check the exhaust system.
REFER to Section 309-00.

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303-00-5 Engine System - General Information 303-00-5

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Engine management system. • Check the engine management
system. REFER to Section 303-
14.
• Fault in ignition system (petrol • Check the ignition system. En-
engines only). gine 1.8L and 2.0L - REFER to
Section 303-07A / 303-07B.
Engine 2.5L and 3.0L -
• Turbocharger (only diesel en- • Check the turbocharger. REFER
gine). to Section 303-04A / 303-04B.
• Incorrect valve timing. Timing • Check and adjust valve timing.
chain or timing sprocket dam- Install new components as nec-
aged. essary. Engine - 1.8L and 2.0L -
REFER to Section 303-01A /
303-01B. Engine - 2.5L - En-
gine - 2.0L Diesel - Engine -
3.0L -
• Noisy running • Engine auxiliary components • Check engine auxiliary compo-
loose or damaged. nents for damage or looseness.
Check and adjust valve timing.
Install new components as nec-
essary. Engine - 1.8L and 2.0L -
REFER to Section 303-01A /
303-01B. Engine - 2.5L - En-
gine - 2.0L Diesel - Engine -
3.0L -
• Noisy running, misfiring, backfir- • Incorrect fuel • Determine which type of fuel
ing or knocking was the last put in the tank (note
the country specific fuel specifi-
cations).
• Water in fuel or fuel contami- • Check the fuel system for water
nated. or other contamination.
• Valve timing incorrect, timing • Check and adjust valve timing.
chain or timing sprocket dam- Install new components as nec-
aged. essary. Engine - 1.8L and 2.0L -
REFER to Section 303-01A /
303-01B. Engine - 2.5L - En-
gine - 2.0L Diesel - Engine -
3.0L -
• Noisy running or valve train • Valve clearance too large due to • Install new hydraulic valve tap-
noise faulty valve tappets or valve pets. Engine - 1.8L and 2.0L -
rocker arms. REFER to Section 303-01A /
303-01B. Engine - 2.5L - En-
gine - 2.0L Diesel - Engine -
3.0L -
• Timing chain damaged. • Install a new timing chain. En-
gine - 1.8L and 2.0L - REFER to
Section 303-01A / 303-01B.
Engine - 2.5L - Engine - 2.0L
Diesel - Engine - 3.0L -

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303-00-6 Engine System - General Information 303-00-6

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Timing chain incorrectly ten- • Check the timing chain tension.
sioned. Install a new tensioner, as nec-
essary. Engine - 1.8L and 2.0L -
REFER to Section 303-01A /
303-01B. Engine - 2.5L - En-
gine - 2.0L Diesel - Engine -
3.0L -
• Timing chain guides worn of • Check the timing chain guides.
damaged. Install new guides as necessary.
Engine - 1.8L and 2.0L - REFER
to Section 303-01A / 303-01B.
Engine - 2.5L - Engine - 2.0L
Diesel - Engine - 3.0L -
• Noisy running or engine block • Engine components • Check the engine components
– Pistons for wear or damage. Make sure
– Piston rings all components are within speci-
– Connecting rod large end, fication. Install new components
main bearing or thrust as necessary. Engine - 1.8L and
bearing journals 2.0L - REFER to Section 303-
– Connecting rods bent or 01A / 303-01B. Engine - 2.5L -
damaged. Engine - 2.0L Diesel - Engine -
3.0L -
5. Check the engine for oil leaks using a
suitable UV lamp.
Engine - Oil Leaks 6. Rectify any leaks found and check the engine
NOTE: Before installing new gaskets or oil seals, for oil leaks.
make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a
Measure the compression pressure (21 111 0)
visual inspection, carry out an ultraviolet (UV)
test: NOTE: The powertrain control module (PCM)
receives an error message when the relay is
removed or electrical components are
Ultraviolet (UV) Testing disconnected. This error message must be
deleted from the fault memory by connecting
1. Clean the engine and transmission with a
WDS after completing the measurement.
suitable cleaning fluid.
NOTE: Valve clearances must be set correctly
2. Pour a suitable UV testing fluid in
before performing a compression test. Make sure
accordance with the quantity specified by the
engine is at the normal operating temperature.
manufacturer through the oil filler neck into
the engine and install the oil filler cap. NOTE: The varying design of compression
checking devices and fluctuating starter motor
WARNING: On manual transmissions put speeds normally only allows to check if the
the transmission into Neutral. Failure to compression is even in all cylinders.
follow these instructions may result in
personal injury.
3. Start the engine and let it run for about five
minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the
vehicle under various loads and check the engine
for leaks again.

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303-00-7 Engine System - General Information 303-00-7

DIAGNOSIS AND TESTING (Continued)

Measure the compression (Engine - 1.8L and 4. Using the special tool, remove the spark plug
2.0L) connectors.

5. Using the special tool, remove the spark

1. Open the central junction box (CJB) and
plugs.
remove the fuel pump relay.
NOTE: The engine will start, run for a few
seconds and then stop.
2. Start the engine.

NOTE: Operate the starter motor with wide open

throttle until the pointer on the measuring device
stops rising.
6. Carry out the measurement in accordance
3. Disconnect the electronic ignition (EI) coil with the instructions supplied with the
electrical connector from the EI coil. measuring device on every cylinder using
compression pressure recorder 623.000.101
with the suitable adapter.

NOTE: Twist the spark plug connectors slightly

before disconnecting them. Pull on the connector
and not on the cable.

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303-00-8 Engine System - General Information 303-00-8

DIAGNOSIS AND TESTING (Continued)

7. Using the special tool, install the spark plugs. 10. Install the fuel pump relay.
11. Reset the PCM fault memory.

Measure the compression (Engine - 2.5L and

3.0L)

8. Install the spark plug connectors.

1. Open the central junction box (CJB) and

remove the fuel pump relay.
NOTE: The engine will start, run for a few
seconds and then stop.
2. Start the engine.

9. Connect the EI coil electrical connector to the

EI coil.

3. Disconnect the electronic ignition (EI) coil

electrical connector from the EI coil.

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303-00-9 Engine System - General Information 303-00-9

DIAGNOSIS AND TESTING (Continued)

4. Remove the engine upper cover. 7. Carry out the measurement in accordance
with the instructions supplied with the
measuring device on every cylinder using
compression pressure recorder 623.000.101.

NOTE: Twist the spark plug connectors slightly

before disconnecting them. Pull on the connector
and not on the cable.
5. Remove the spark plug connectors. 8. Using the special tool, install the spark plugs.

6. Using the special tool, remove the spark 9. Install the spark plug connectors.
plugs.

NOTE: Operate the starter motor with wide open

throttle until the pointer on the measuring device
stops rising.

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303-00-10 Engine System - General Information 303-00-10

DIAGNOSIS AND TESTING (Continued)

10. Install the engine upper cover. 1. Open the central junction box (CJB) and
remove the glow plug relay.
2. Remove the Intake Manifold. REFER to
Section 303-01A / 303-01B.

11. Connect the EI coil electrical connector to

the EI coil.

3. Disconnect the fuel injector electrical

connectors from the fuel injectors (vehicles
with common rail fuel injection).

12. Install the fuel pump relay.

13. Reset the PCM fault memory.

Measure the compression (Engine - 2.0L 4. Disconnect the fuel injection pump electrical
Diesel) connector from the fuel injection pump
(vehicles without common rail fuel injection).

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303-00-11 Engine System - General Information 303-00-11

DIAGNOSIS AND TESTING (Continued)

5. Disconnect the glow plug wire electrical 9. Carry out the measurement on all cylinders,
connector. following the measuring equipment
manufacturer's instructions.
10. Detach the compression tester and
adapter.

6. Disconnect the glow plug electrical

connector.

11. Install the glow plugs.

7. Remove the glow plugs.

12. Connect the glow plug electrical

connector.

8. Install compression tester 623.002.1101 with

adapter GV2168 into the glow plug bore.
NOTE: Crank the engine with the starter motor
until the reading on the compression tester stops
rising.

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303-00-12 Engine System - General Information 303-00-12

DIAGNOSIS AND TESTING (Continued)

13. Connect the glow plug wire electrical 17. Install the glow plug relay.
connector. 18. Reset the PCM fault memory.

Oil Pressure - Measure (21 113 0)

The oil pressure depends on various factors
(engine speed, oil temperature, oil viscosity,
extent of oil filter contamination etc.).
NOTE: Measure the oil pressure at the specified
engine speed. Measure the oil pressure at an oil
temperature of 80°C.

14. Connect the fuel injector electrical Measure the oil pressure (Engine - 1.8L and
connectors to the fuel injectors (vehicles with 2.0L)
common rail fuel injection). 1. Raise and support the vehicle. REFER to
Section 100-02.

15. Connect the fuel injection pump electrical

connector to the fuel injection pump (vehicles 2. Remove the radiator lower cover.
without common rail fuel injection).
16. Install the Intake Manifold. REFER to
Section 303-01A / 303-01B.

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303-00-13 Engine System - General Information 303-00-13

DIAGNOSIS AND TESTING (Continued)

3. Disconnect the oil pressure switch electrical 7. Measure the oil pressure.
connector from the oil pressure switch. 8. Raise and support the vehicle. REFER to
Section 100-02.

4. Remove the oil pressure switch.

9. Detach the oil pressure gauge and connector
from the oil pressure switch bore.
10. Coat the oil pressure switch with sealant
(WSK-M2G349-A7).

5. Attach the oil pressure gauge (GV 2134) with

the oil pressure gauge connector to the oil
pressure switch bore, and position it to allow
reading from above.
6. Lower the vehicle. 11. Install the oil pressure switch.

NOTE: Oil pressure at 2000 rpm: 3.5 bar.

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303-00-14 Engine System - General Information 303-00-14

DIAGNOSIS AND TESTING (Continued)

12. Connect the oil pressure switch electrical 3. Disconnect the oil pressure switch electrical
connector to the oil pressure switch. connector from the oil pressure switch.

13. Install the radiator lower cover. 4. Remove the oil pressure switch.
14. Lower the vehicle.

Measure the oil pressure (Engine - 2.5L and

3.0L)
1. Raise and support the vehicle. REFER to
Section 100-02.

5. Attach the oil pressure gauge (GV 2134) with

oil pressure gauge connector to the oil
pressure switch bore, and position it to allow
reading from above.
6. Lower the vehicle.

2. Remove the radiator lower cover.

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303-00-15 Engine System - General Information 303-00-15

DIAGNOSIS AND TESTING (Continued)

7. Measure the oil pressure. Engine - 2.5L - 13. Install the radiator lower cover.
REFER to Section 303-01A / 303-01B. 14. Lower the vehicle.
Engine - 3.0L -
8. Raise and support the vehicle. REFER to
Section 100-02. Measure the oil pressure (Engine - 2.0L
9. Detach the oil pressure gauge and connector Diesel)
from the oil pressure switch bore. 1. Raise and support the vehicle. REFER to
10. Coat the oil pressure switch with sealant Section 100-02.
(WSK-M2G349-A7).

2. Remove the engine undershield.

11. Install the oil pressure switch.

3. Remove the radiator lower cover.

12. Connect the oil pressure switch electrical
connector to the oil pressure switch.

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303-00-16 Engine System - General Information 303-00-16

DIAGNOSIS AND TESTING (Continued)

4. Disconnect the oil pressure switch electrical 8. Measure the oil pressure. REFER to Section
connector from the oil pressure switch. 303-01A / 303-01B.
9. Raise and support the vehicle. REFER to
Section 100-02.

5. Remove the oil pressure switch.

10. Remove the oil pressure gauge and the

oil pressure gauge connector.
11. Coat the oil pressure switch with sealant
(WSK-M2G349-A7).

6. Attach the oil pressure gauge (GV 2134) with

the oil pressure gauge connector, and
position it to allow reading from above.
7. Lower the vehicle.

12. Install the oil pressure switch.

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303-00-17 Engine System - General Information 303-00-17

DIAGNOSIS AND TESTING (Continued)

13. Connect the oil pressure switch electrical

connector to the oil pressure switch.

14. Install the engine undershield.

15. Install the radiator lower cover.

16. Lower the vehicle.

Valve train analysis - static (engine off)

Remove the valve cover.
Check all components of the valve train for
damage and wear. Make sure that only original
components are installed and that all nuts and
bolts are tightened to the specified torque.

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303-00-18 Engine System - General Information 303-00-18

GENERAL PROCEDURES

Camshaft Bearing Journal Diameter

GENERAL PROCEDURES

1. Determine the diameter of the camshaft

journals.
• Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
• Measure at two different points on the
journal to determine if there is any tapering.
• If the measurements are out of the speci-
fied range, install a new camshaft.

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303-00-19 Engine System - General Information 303-00-19

GENERAL PROCEDURES

Camshaft Bearing Journal Clearance

1. NOTE: Make sure that the following stages are 4. Using the Plastigage, read off the
followed exactly. The tappets or followers measurement.
must be removed to carry out this • Compare the width of plastigage with the
measurement. plastigage scale.
NOTE: Make sure that the camshaft is to • The value that is read off is the bearing
specification. clearance.
NOTE: The bearing caps and journals should be
free from engine oil and dirt.
Position on a width of plastigage on the
bearing cap.
• Insert the camshaft, without lubrication, into
the cylinder head.
• Position a plastigage strip, which should be
equal to the width of the bearing cap, on
the bearing journal.

2. Following the tightening specification,

install the camshaft bearing caps. Refer to
the corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps, refer
to the corresponding Section 303-01.

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303-00-20 Engine System - General Information 303-00-20

GENERAL PROCEDURES

Camshaft End Play

1. NOTE: Make sure that the camshaft is to

specification.
Using a Dial Indicator Gauge, measure the
end play.
• Slide the camshaft in both directions. Read
and note the maximum and minimum
values on the Dial Indicator Gauge.
• End play = maximum value minus
minimum value
• If the measurement is out of specification,
install new components.

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303-00-21 Engine System - General Information 303-00-21

GENERAL PROCEDURES

Camshaft Surface Inspection

1. Inspect the camshaft lobes for pitting or

damage in the active area. Minor pitting is
acceptable outside the active area.

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303-00-22 Engine System - General Information 303-00-22

GENERAL PROCEDURES

Camshaft Lobe Lift

1. Determine the cam lift.

• Using a micrometer measure the cam in
two directions.
• The difference between the two measure-
ments is the cam lift.

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303-00-23 Engine System - General Information 303-00-23

GENERAL PROCEDURES

Crankshaft Main Bearing Journal Clearance

1. Information not available at time of going

to press.

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303-00-24 Engine System - General Information 303-00-24

GENERAL PROCEDURES

Crankshaft Main Bearing Journal Diameter

General Equipment
Micrometer
1. Measure the diameter of the main bearing
journals and the big-end bearing journals.
• Repeat the measurement with the
micrometer offset by 90°, in order to
determine any eccentricity which may be
present.
• Measure the journal at two different posi-
tions to determine any conicity which may
be present.

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303-00-25 Engine System - General Information 303-00-25

GENERAL PROCEDURES

Crankshaft End Play

General Equipment
Dial indicator
Dial indicator fixture
1. NOTE: Operation for vehicles with Zetec-E
engines only. Dismantling the crank gear is
not permitted on Zetec-SE engines.
Determine the end float
• Place on the dial indicator and bracket .
• Determine the end float by raising the
crankshaft with the aid of a screwdriver.
• If necessary, correct the end float by using
new thrust half washers.

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303-00-26 Engine System - General Information 303-00-26

GENERAL PROCEDURES

Cylinder Bore Taper

1. NOTE: The main bearing caps or lower

crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
• Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness
or tapering.
• If the measurement is out of the specified
range, install a new block or hone out the
cylinder block (if aplicable/allowed).

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303-00-27 Engine System - General Information 303-00-27

GENERAL PROCEDURES

Piston Inspection

1. CAUTION: Do not use any aggressive

cleaning fluid or a wire brush to clean
the piston.
Carry out a visual inspection.
• Clean the piston skirt, pin bush, ring
grooves and crown and check for wear or
cracks.
• If there are signs of wear on the piston
skirt, check whether the connecting rod is
twisted or bent.

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303-00-28 Engine System - General Information 303-00-28

GENERAL PROCEDURES

Piston Pin to Bore Diameter

1. NOTE: The piston and piston pin form a

matched pair. Do not mix up the components.
Measure the diameter of the piston pin
bore.
• Measure the diameter in two directions.
• If the values are not to specification, install
both a new piston and a new piston pin.

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303-00-29 Engine System - General Information 303-00-29

GENERAL PROCEDURES

Piston Diameter

General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the
piston is installed correctly.
Using a Micrometer measure the piston
diameter.

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303-00-30 Engine System - General Information 303-00-30

GENERAL PROCEDURES

Piston Ring End Gap

1. CAUTION: Do not mix up the piston

rings. Install the piston rings in the
same position and location.
Take the piston ring and use a piston
without rings to push the piston ring about
30 mm into the cylinder bore.

2. Using the Feeler Gauge, measure the pis-

ton ring gap.

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303-00-31 Engine System - General Information 303-00-31

GENERAL PROCEDURES

Piston Ring-to-Groove Clearance

General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from the
piston groove. To determine the piston ring
clearance, insert the Feeler Gauge right to the
back of the groove, behind the wear ridge.
Using the Feeler Gauge , measure the pis-
ton ring clearance.

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303-00-32 Engine System - General Information 303-00-32

GENERAL PROCEDURES

Piston Pin Diameter

1. NOTE: The piston and piston pin are a

matched pair. Do not mix up the components.
Measure the piston pin diameter.
• Measure the diameter in two directions.
• If the values are not to specification, install
a new piston and a new piston pin.

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303-00-33 Engine System - General Information 303-00-33

GENERAL PROCEDURES

Connecting Rod Large End Bore

1. Measure the bearing bore in two direc-

tions. The difference is the connecting rod
bore out-of-round. Verify the out-of-round
and the bearing bore is within specifica-
tion.

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303-00-34 Engine System - General Information 303-00-34

GENERAL PROCEDURES

Valve Stem Diameter

1. Using a micrometer measure the diameter

of the valve stems.
• If the measurements are not to specifica-
tion, install a new valve.

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303-00-35 Engine System - General Information 303-00-35

GENERAL PROCEDURES

Valve Seat Inspection

General Equipment
Valve seat width scale
1. Measure the width of the valve seat.
• Measure the valve seat width using the
Valve seat width scale.
• If the value is not to specification rework
the valve seat.

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303-00-36 Engine System - General Information 303-00-36

GENERAL PROCEDURES

Cylinder Head Distortion

General Equipment
Feeler Gauge
Straight edge

1. CAUTION: The mating face of the 2.5L

engines must not be reworked.
Using a straight edge and feeler gauge,
measure the cylinder head distortion.
• Measure the mating face distortion.
• If the value is not to specification rework
the mating face.

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303-00-37 Engine System - General Information 303-00-37

GENERAL PROCEDURES

Cylinder Block Distortion

1. Using a Straight Edge and a Feeler Gauge,

measure the cylinder block/cylinder head
distortion.
• Measure the mating face distortion.
• If the value is not to specification rework
the mating face (if allowed).

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303-00-38 Engine System - General Information 303-00-38

GENERAL PROCEDURES

Exhaust Manifold Cleaning and Inspection

1. Inspect the cylinder head joining flanges

of the exhaust manifold for evidence of
exhaust gas leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other
damage that would make it unfit for further
use.

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303-00-39 Engine System - General Information 303-00-39

GENERAL PROCEDURES

Bearing Inspection

1. Inspect bearings for the following defects.

1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing
not seated.

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303-01A-1 Engine 303-01A-1

SECTION 303-01A Engine

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-01-3

Engine Data 1.8L 110 PS ................................................................................................. 303-01-3
Engine Data 1.8L 125 PS ................................................................................................. 303-01-3
Engine Data 2.0L 145 PS ................................................................................................. 303-01-3
Engine Oil......................................................................................................................... 303-01-3
Oil system ........................................................................................................................ 303-01-3
Engine Oil Capacity.......................................................................................................... 303-01-4
Valve Dimensions............................................................................................................. 303-01-4
Camshaft Dimensions ...................................................................................................... 303-01-4
Crankshaft Dimensions .................................................................................................... 303-01-4
Piston Dimensions, 1.8L Engine....................................................................................... 303-01-4
Piston Dimensions, 2.0L Engine....................................................................................... 303-01-4
Piston Ring Dimensions ................................................................................................... 303-01-4
Cylinder Block .................................................................................................................. 303-01-4
Connecting Rod Dimensions ............................................................................................ 303-01-5

DESCRIPTION AND OPERATION

Engine ............................................................................................................................... 303-01-7

DIAGNOSIS AND TESTING

Engine ............................................................................................................................... 303-01-16

GENERAL PROCEDURES

Valve Clearance Adjustment ............................................................................................. 303-01-17

IN-VEHICLE REPAIR

Intake Manifold ............................................................................................. (21 183 0) 303-01-21

Crankshaft Front Seal................................................................................... (21 467 0) 303-01-24
Valve Seals .................................................................................................. (21 238 0) 303-01-33
Valves .......................................................................................................... (21 215 4) 303-01-35
Camshafts .................................................................................................... (21 284 0) 303-01-37
Timing Chain ................................................................................................ (21 314 0) 303-01-47
Cylinder Head............................................................................................... (21 163 0) 303-01-60
Oil Pan ......................................................................................................... (21 154 0) 303-01-77
Oil Pump ...................................................................................................... (21 714 0) 303-01-91
Crankshaft Rear Seal ................................................................................... (21 468 4) 303-01-93

REMOVAL AND INSTALLATION

Engine — Vehicles With: Automatic Transaxle .................................................................. 303-01-95

DISASSEMBLY

Engine .......................................................................................................... (21 134 8) 303-01-105

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303-01A-2 Engine 303-01A-2

ASSEMBLY

Engine........................................................................................................... (21 134 8) 303-01-113

INSTALLATION

Engine — Vehicles With: Automatic Transaxle................................................................... 303-01-126

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303-01A-3 Engine — 1.8L/2.0L 303-01A-3

SPECIFICATIONS

Engine Data 1.8L 110 PS

Description
Firing order 1-3-4-2
Bore diameter 83 mm
Stroke 83.1 mm
Compression ratio 10.8 : 1
Engine performance (EEC) – 5500 rpm 81 kW (110 PS)
Torque at 3950 rpm 165 Nm
Maximum permissible engine speed — intermittent 6175 rpm
Fuel shut off 6925 rpm

Engine Data 1.8L 125 PS

Description
Firing order 1-3-4-2
Bore diameter 83 mm
Stroke 83.1 mm
Compression ratio 10.8 : 1
Engine performance (EEC) – 6000 rpm 92 kW (125 PS)
Torque at 4500 rpm 170 Nm
Maximum permissible engine speed — intermittent 6800 rpm
Fuel shut off 6925 rpm

Engine Data 2.0L 145 PS

Description
Firing order 1-3-4-2
Bore diameter 87.5 mm
Stroke 83.1 mm
Compression ratio 10.8 : 1
Engine performance (EEC) – 6000 rpm 107 kW (145 PS)
Torque at 4500 rpm 190 Nm
Maximum permissible engine speed — intermittent 6675 rpm
Fuel shut off 6925 rpm

Engine Oil
Viscosity / ambient
temperature Type Specification
Recommended engine oil
SAE 5W-30 / below -20°C to over Ford Formula E Economy Motor ACEA A1/B1 and WSS-M2C912-
+40°C Oil A1 or WSS-M2C913-A
Alternative engine oils
SAE 10W-30 / -20°C to over Ford Super Multigrade Motor Oil ACEA A1/B1 or A2/B2 and/or
+40°C API/SH/CD EC
SAE 10W-40 / -20°C to over Ford XR+ High-performance ACEA A3/B3 and/or API/SH/CD
+40°C High-lubricity Motor Oil EC
SAE 5W-40 / below -20°C to over Ford Formula S Synthetic Motor ACEA A3/B3 and/or API/SH/CD
+40°C Oil EC
If engine oils with these specifications are not available, only use engine oils which conform to specification API
SH/EC (Energy Conserving) or better.

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303-01A-4 Engine — 1.8L/2.0L 303-01A-4

SPECIFICATIONS (Continued)

Oil system
Description bar
Pressure relief valve opening pressure 5
If other types of engine oil are used, these must conform at least to the respective API SH/EC viscosity class.

Engine Oil Capacity

Description Liters
Initial fill, including oil filter 4.6
Service fill including filter 4.3
Service fill excluding filter 3.9

Valve Dimensions
Description mm
Valve clearance (engine cold), intake 0.22 – 0.28
Valve clearance (engine cold), exhaust 0.27 – 0.33
Valve stem diameter, intake 5.465 - 5.480
Valve stem diameter, exhaust 5.470 - 5.485

Camshaft Dimensions
Description mm
Camshaft journal diameter 24.97 ± 0.01
Camshaft journal clearance 0.055 - 0.060
Camshaft endplay 0.09 - 0.24
Camshaft lobe lift, intake, 81 kW (110 PS) 7.4
Camshaft lobe lift, intake, 92 kW (125 PS) 8.5
Camshaft lobe lift, intake, 107 kW (145 PS) 8.8
Camshaft lobe lift, exhaust 7.7

Crankshaft Dimensions
Description mm
Crankshaft main bearing journal 0.019 - 0.035
Crankshaft main bearing journal diameter 57.018 - 57.040
Crankshaft endplay 0.335 ± 0.115

Piston Dimensions, 1.8L Engine

Description mm
Piston diameter - Class 1 82.965 - 82.975
Piston diameter - Class 2 82.975 - 82.985
Piston diameter - Class 3 82.985 - 82.995

Piston Dimensions, 2.0L Engine

Description mm
Piston diameter - Class 1 87.465 - 87.475
Piston diameter - Class 2 87.475 - 87.485
Piston diameter - Class 3 87.485 - 87.495

Piston Ring Dimensions

Description mm
Piston ring end gap (oil control ring) 0.2 - 0.7

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303-01A-5 Engine — 1.8L/2.0L 303-01A-5

SPECIFICATIONS (Continued)

Cylinder Block
Description mm
Cylinder bore diameter, 1.8L Engine 83.000 + 0.030
Cylinder bore diameter, 2.0L Engine 87.500 + 0.030
Cylinder block distortion (maximum) 0.1

Connecting Rod Dimensions

Description mm
Large end bore diameter 50.035 ± 0.01

Torque Specifications
Description Nm lb-ft lb-in
Cylinder head retaining bolts a) – –
Timing chain guide retaining bolts 10 – 89
Camshaft bearing caps retaining bolts a) – –
Camshaft sprocket retaining bolts 65 48 –
Camshaft position (CMP) sensor retaining bolt 6 - 53
Engine front cover retaining bolts a) – –
Crankshaft pulley retaining bolts a) – –
Coolant expansion tank retaining nut 10 – 89
Coolant plug to cylinder block 43 32 -
Coolant plugs (4) to cylinder head 75 55 -
Power steering pump retaining bolt 23 17 –
Power steering reservoir retaining bolts 25 18 –
Power steering reservoir retaining nut 10 – 89
Power steering pipe to the power steering 65 48 –
Power steering bracket retaining nut 15 11 –
Exhaust manifold bracket retaining bolts 25 18 –
Exhaust manifold upper heat shield retaining bolts 10 – 89
Exhaust manifold lower heat shield retaining bolts 10 – 89
Exhaust manifold to the cylinder head 55 41 –
Exhaust manifold studs to cylinder head 17 13 -
Exhaust gas recirculation (EGR) tube to cylinder 55 41 -
head
Water pump pulley retaining bolts 25 18 –
Valve cover retaining bolts 10 – 89
Oil pressure switch 15 11 -
Oil pump retaining bolts a) – –
Oil pan retaining bolts 25 18 –
Oil cooler to oil filter adaptor retaining bolt 34 25 -
Crankshaft rear oil seal retaining bolts 10 – 89
Flywheel retaining bolts a) – –
Oil filter adaptor retaining bolts 25 18 –
Positive crankcase ventilation housing retaining 10 – 89
bolts
Knock sensor retaining bolt 20 15 –
Thermostat housing retaining bolts 10 – 89
Water pump retaining bolts 10 – 89
Oil pump sprocket retaining bolt 25 18 –
Oil pump chain guide retaining bolts 10 – 89

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303-01A-6 Engine — 1.8L/2.0L 303-01A-6

SPECIFICATIONS (Continued)

Description Nm lb-ft lb-in

Oil pump chain tensioner retaining bolt 10 – 89
Timing chain guide retaining bolts 10 – 89
Crankshaft position sensor retaining bolts 7 – 62
Accessory drive belt idler pulley retaining bolt 25 18 –
Intake manifold retaining bolts 18 13 –
Transaxle retaining bolts 44 32 –
Transaxle right–hand retaining bolts 44 32 –
Halfshaft center bearing carrier retaining bolts 48 35 –
Intermediate shaft bearing cap retaining nuts 25 18 –
Starter motor retaining bolts 35 26 –
Wiring harness retaining bracket nuts 20 15 –
A/C compressor retaining bolts 25 18 –
Engine rear mount retaining nut 80 59 –
Engine front mount studs to front cover 10 89
Engine front mount retaining bolts 80 59 –
Top mount retaining nut 59 44 –
Piston cooling jets 4 - 35
a) Refer to the procedure in this section.

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Sealant, oil pan contact surface to oil seal carrier, oil pan to cylinder block, WSE–M4G323–A6
oil pan to front cover
Oil pressure switch sealant (Loctite 243) WSK–M2G349–A7
Engine front cover blanking plug sealant (3M 2510) ESS–M11P24–A1
Anti–seize grease ESE–M1244–A
Power steering fluid ESP–M2C166–A
Silicone grease ESE–M1C171–AA

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303-01A-7 Engine — 1.8L/2.0L 303-01A-7

DESCRIPTION AND OPERATION

Engine
DESCRIPTION AND OPERATION

The vehicle is available with the Duratec-HE Apart from increasing the torque and power
range of petrol engines which supersedes the output, the development objectives were to
Zetec-E range of engines. reduce the engine weight, noise emissions, fuel
consumption and pollutant emissions.
This range of engines has been developed by
Ford in collaboration with Mazda in Japan. Two variants are available with a total of three
different power output levels:
The engines are built in the Ford engine plants at
Dearborn (USA) and Chihuahua (Mexico).

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303-01A-8 Engine — 1.8L/2.0L 303-01A-8

DESCRIPTION AND OPERATION (Continued)

• 1.8L engine developing 81 kW (110 PS) the deep-drawn side walls of the cylinder block
• 1.8L engine developing 92 kW (125 PS) which reduce engine vibration.
• 2.0L engine developing 107 kW (145 PS) The camshafts are driven by a pinned link chain
which runs very quietly and is also maintenance-
The complete engine is made of cast aluminum
free.
which, when combined with the plastic intake
manifold, gives a very light unit. For the first time on a Ford product, the engine
management for the Duratec-HE is provided by a
NOTE: Because of the fine tolerance in the
Visteon Black Oak system.
bearing clearances and bearing shells, no service
operations whatsoever are permitted on the This engine management systems controls the
crank assembly. In the event of damage, the sequential multipoint fuel injection (SFI), the
complete cylinder block and crank assembly electrically heated thermostat and the
must be changed. electronically controlled water-cooled exhaust
gas recirculation (EGR) valve.
Further design features include a stiffening frame
incorporating the main bearing caps which In addition, the Black Oak system also controls
support the crankshaft in the cylinder block, and the swirl of the combustion air flowing into the
cylinders by means of swirl plates.

Engine codes

Item Part Description

Item Part Description Number
Number
1 – CJBB code for 2.0L/107 kW
1 – CGBA code for 1.8L/81 kW engine, Germany, stage IV,
engine, Europe stage III, 2001.5 MY
2000.1 MY
2 – Engine serial number
1 – CGBB code for 1.8L/81 kW
engine, Germany, stage IV,
2001.5 MY
1 – CHBA code for 1.8L/92 kW
engine, Europe, stage III,
2001.5 MY
1 – CHBB code for 1.8L/92 kW
engine, Germany, stage IV,
2001.5 MY
1 – CJBA code for 2.0L/107 kW
engine, Europe, stage III,
2001.5 MY

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303-01A-9 Engine — 1.8L/2.0L 303-01A-9

DESCRIPTION AND OPERATION (Continued)

Cylinder head The cylinder head gaskets for the different engine
variants are marked as follows:
• 1.8L: 2 trapezoidal marks
• 2.0L: 1 trapezoidal mark
The cylinder head gasket and cylinder head are
located with two locating dowels.

Bucket tappets

Item Part Description

Number
1 – Exhaust camshaft
2 – Bearing cap
3 – Cam to identify cylinder No.
1
4 – Intake camshaft
Item Part Description
5 – Camshaft sprockets Number
The design and the valve arrangement in the 1 – Exhaust valve tappet
cylinder head is similar to the head of the Zetec- 2 – Intake valve tappet
SE engines.
Mechanical tappets are fitted without adjusting
shims.
Cylinder head gasket
Because of the special materials and the
optimized cam profiles, the wear in the area of
the valve gear is so minute that checking and
adjustment of the valve clearances is only
necessary after the engine has been in extensive
service.
Different sizes of replacement bucket tappets are
available in the event of wear or repairs to the
valve gear.

Item Part Description

Number
1 – Mark
2 – Locating dowels

A four-layer laminated steel cylinder head gasket

is used.

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303-01A-10 Engine — 1.8L/2.0L 303-01A-10

DESCRIPTION AND OPERATION (Continued)

Camshaft drive Item Part Description
Number
1 – Exhaust camshaft sprocket
2 – Timing chain
3 – Intake camshaft sprocket
4 – Chain guide
5 – Crankshaft sprocket
6 – Hydraulic chain tensioner
7 – Chain tensioner arm

The camshafts are driven by a low-noise,

maintenance-free pinned link timing chain.
This is lubricated by the engine oil circuit.
An elongated chain guide and a chain tensioner
arm ensure optimum chain guidance and silent
running.
The chain is tensioned by a hydraulic chain
tensioner which is supplied from the engine oil
circuit.
The chain tensioner can be used again after
removal.
The camshaft drive requires no maintenance.

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303-01A-11 Engine — 1.8L/2.0L 303-01A-11

DESCRIPTION AND OPERATION

Front cover

The camshaft drive is sealed with an aluminum

Item Part Description front cover.
Number
The crankshaft oil seal is inserted in this front
1 – Front cover cover.
2 – Crankshaft oil seal The front cover is installed using sealer.
3 – Sealer for sealing at bores
4 – Sealer for sealing cover

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303-01A-12 Engine — 1.8L/2.0L 303-01A-12

DESCRIPTION AND OPERATION

Intake manifold

Item Part Description

Item Part Description Number
Number
5 – Swirl plate vacuum dia-
1 – Exhaust gas recirculation phragm unit
gasket
6 – Actuating linkage
2 – Intake port gasket
The plastic intake manifold incorporates swirl
3 – Swirl plate plates which reduce the cross-section of the
4 – Connecting pipe intake passages at low speeds.

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303-01A-13 Engine — 1.8L/2.0L 303-01A-13

DESCRIPTION AND OPERATION (Continued)

The measure produces increased intake air swirl When the engine is switched off, the swirl plates
at low engine speeds. are closed.
The increased intake air swirl makes the mixture The intake manifold is sealed by a total of five
ignite more readily around the spark plug, which rubber gaskets (four gaskets for the intake ports
ultimately reduces fuel consumption and exhaust and one gasket for the exhaust gas recirculation)
emissions. which are inserted and held in position and must
be changed if serviced.
The swirl plates are adjusted by means of a
vacuum diaphragm unit on the intake manifold. The recirculated exhaust gas is distributed
uniformly between all four intake ports through a
The system is actuated by a solenoid valve.
connecting pipe (incorporated in the intake
The swirl plates are designed so that they allow manifold).
the required quantity of air to flow past.

Crankshaft vibration damper

The crankshaft vibration damper forms a unit with

Item Part Description the rotor for indicating the crankshaft position.
Number
It is secured to the crankshaft by the contact
1 – Crankshaft pressure of the retaining bolt (free to turn on the
2 – Crankshaft oil seal seat on the crankshaft).

3 – Front cover The retaining bolt must be changed after

removal.
4 – Crankshaft vibration damper
The vibration damper is positioned with the aid of
5 – Retaining bolt an M6 bolt.
6 – M6 bolt

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303-01A-14 Engine — 1.8L/2.0L 303-01A-14

DESCRIPTION AND OPERATION (Continued)

NOTE: The M6 bolt must never be used as
support when tightening the retaining bolt as this
could damage the timing cover.

Oil pump

Item Part Description

Number
1 – Crankshaft sprocket
2 – Spring-loaded chain ten-
sioner
3 – Oil pump sprocket
4 – Driving chain
5 – Chain guide
The oil pump is mounted on the cylinder block on
the timing case side at the bottom and driven
directly from the crankshaft by a separate driving
chain.
A chain guide and a spring-loaded chain
tensioner ensure quiet maintenance-free
operation.
Item Part Description
Number
1 – Oil pump
2 – Gasket
3 – Outer rotor
4 – Inner rotor
A rotor oil pump is used for engine lubrication on
the Duratec-HE engines.
The rotor oil pump is a positive displacement
pump with an internally toothed outer rotor and
an externally toothed inner rotor.
The rotor pump works very evenly, can produce
high pressures and is therefore fundamental for
optimum engine lubrication.

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303-01A-15 Engine — 1.8L/2.0L 303-01A-15

DESCRIPTION AND OPERATION (Continued)

Oil filter Engine oil cooler

Item Part Description

Number
1 – Retaining bolt
2 – Oil cooler
3 – Oil filter housing
An engine oil cooler is also installed in
combination with the automatic transmission
(CD4E) in some markets due to the climatic
conditions.
This is mounted on the oil filter housing with a
retaining bolt and sealed with an O-ring seal.
Item Part Description
Number
1 – Gasket
2 – Oil pressure switch
3 – Oil filter housing
4 – Oil filter element
5 – O-ring seal
6 – Oil filter cap
An oil filter housing with an integral filter element
is used on the Duratec-HE engines.
The oil filter housing is mounted on the cylinder
block with a gasket.
For service this means that only the oil filter
element itself and the O-ring seal on the oil filter
cap must be changed.

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303-01A-16 Engine — 1.8L/2.0L 303-01A-16

DIAGNOSIS AND TESTING

Engine
DIAGNOSIS AND TESTING

REFER to Section 303-00.

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303-01A-17 Engine — 1.8L/2.0L 303-01A-17

GENERAL PROCEDURES

Valve Clearance Adjustment

GENERAL PROCEDURES

3. Disconnect the battery ground cable. For

additional information, refer to Section
414-01.
Special Tool(s)
4. Disconnect the camshaft position (CMP)
Socket, Spark Plug sensor electrical connector.
303-499 (21-202)

Pliers. Valve Stem Oil Seal

303-508 (21-211)

General Equipment
Feeler gauges
1. Detach the positive crankcase ventilation 5. Detach the engine wiring harness electri-
(PCV) hose and the vacuum hose from the cal connector from the valve cover.
engine upper cover.

6. Detach the PCV hose from the valve cover.

2. Remove the engine upper cover.

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303-01A-18 Engine — 1.8L/2.0L 303-01A-18

GENERAL PROCEDURES (Continued)

7. Remove the engine upper cover retaining 10. Remove the valve cover.
brackets.

11. CAUTION: Only turn the engine in the

8. Using the special tool, disconnect the normal direction of rotation.
spark plug electrical connectors.
Turn the engine until piston No. 1 is at
top dead center (TDC).
12. NOTE: Note down each cylinder number and
the valve clearances measured.
Using a suitable set of feeler gauges,
measure the valve clearances.

9. Using the special tool, remove the spark

plugs.

13. CAUTION: Only turn the engine in the

normal direction of rotation.
Turn the engine until each piston is at
TDC and measure the valve clearances.
14. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment. For additional information, refer
to Specifications in this section.
Remove the camshafts. For additional
information, refer to Camshafts in this
section.

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303-01A-19 Engine — 1.8L/2.0L 303-01A-19

GENERAL PROCEDURES (Continued)

15. NOTE: The number on the valve tappet 20. NOTE: Install a new valve cover gasket if
indicates the valve tappet thickness. necessary.
Determine the valve tappet thickness Install the valve cover.
required: • Tighten the bolts in the sequence shown.
1. Remove the valve tappet and read the
thickness from the underside.
2. Valve tappet thickness required = thickness
of currently installed valve tappet + the
measured valve clearance - the required
valve clearance. For additional
information, refer to Specifications in this
section.
3. Install the correct valve tappet.
16. NOTE: Do not install the valve cover at this
stage.
Install the camshafts. For additional
information, refer to Camshafts in this
section.
21. Using the special tool, install the spark
17. CAUTION: Only turn the engine in the plugs.
normal direction of rotation.
Turn the engine until each piston is at
TDC and measure the valve clearances.
18. Repeat this procedure as necessary until
all valve clearances are within the
specified tolerance.
19. Apply a small bead of silicon sealantto
the areas as shown.

22. Using the special tool, connect the spark

plug electrical connectors.

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303-01A-20 Engine — 1.8L/2.0L 303-01A-20

GENERAL PROCEDURES (Continued)

23. Install the engine upper cover retaining 26. Attach the engine wiring harness electri-
brackets. cal connector to the valve cover.

24. Attach the PCV hose to the valve cover. 27. Connect the battery ground cable. For
additional information, refer to Section
414-01.
28. Install the engine upper cover.

25. Connect the CMP sensor electrical con-

nector.

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303-01A-21 Engine — 1.8L/2.0L 303-01A-21

IN-VEHICLE REPAIR

Intake Manifold (21 183 0)

IN-VEHICLE REPAIR

5. Remove the oil level indicator lower retain-

ing bolt.
Special Tool(s)
Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

Removal
1. Detach the positive crankcase ventilation
(PCV) hose and the vacuum hose from the
engine upper cover.
6. Remove the intake manifold lower retain-
ing bolt.

2. Remove the engine upper cover.

7. Lower the vehicle.

8. Detach the air cleaner outlet pipe from the
throttle body (TB).

3. Disconnect the battery ground cable.

For additional information, refer to Section
414-01.
4. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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303-01A-22 Engine — 1.8L/2.0L 303-01A-22

IN-VEHICLE REPAIR (Continued)

9. Detach the accelerator cable. 12. Disconnect the electrical connectors.
1. Detach the inner cable.
2. Turn the cable out of the bracket.
• Detach the cable and position it to one
side.

13. Detach the engine wiring harness from

the intake manifold.

10. Disconnect the throttle position (TP) sen-

sor and the idle air control (IAC) valve
electrical connectors.

14. Remove the oil level indicator and tube.

11. Disconnect the brake booster vacuum

line from the intake manifold.

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303-01A-23 Engine — 1.8L/2.0L 303-01A-23

IN-VEHICLE REPAIR (Continued)

15. Disconnect the vacuum hoses from the 19. Detach the knock sensor (KS) electrical
intake manifold. connector from the intake manifold.
20. Remove the intake manifold.

Installation
1. NOTE: Install new gaskets.
To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

16. Disconnect the engine air shut off valve,

the manifold absolute pressure (MAP)
sensor and the swirl plates solenoid
valve electrical connectors.
17. Remove the intake manifold bolts (engine
shown removed for clarity).
• Detach the intake manifold from the cylin-
der head.

18. Disconnect the PCV hose from the intake

manifold.

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303-01A-24 Engine — 1.8L/2.0L 303-01A-24

IN-VEHICLE REPAIR

Crankshaft Front Seal (21 467 0)

Special Tool(s)
Pliers, Valve Stem Oil Seal
Special Tool(s) 303-508 (21-211)
Adapter for 205-071 (15-
026A)
205-071-02 (15-026-51)
Remover, Halfshaft Oil Seal
308-208 (16-074)
Flange Holding Wrench,
Universal
205-072 (15-030A)

General Equipment

Adapter for 205-072 M6 x 18 mm bolt

205-072-02 (15-030A-02)
Removal
1. Detach the positive crankcase ventilation
Remover, Crankshaft Oil (PCV) hose and the vacuum hose from the
Seal engine upper cover.
303-293(21-143)

Timing Plate, Camshaft

Alignment
303-376 (21-162B)

Installer, Crankshaft Oil Seal

303-395 (21-171)

2. Remove the engine upper cover.

Remover/Installer, Spark
Plug
303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

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303-01A-25 Engine — 1.8L/2.0L 303-01A-25

IN-VEHICLE REPAIR (Continued)

3. Disconnect the battery ground cable. For 7. Remove the engine upper cover retaining
additional information, refer to Section brackets.
414-01.
4. Disconnect the camshaft position (CMP)
sensor electrical connector.

8. Using the special tool, disconnect the

spark plug electrical connectors.

5. Detach the engine wiring harness electri-

cal connector from the valve cover.

9. Using the special tool, remove the spark

plugs.

6. Detach the PCV hose from the valve cover.

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303-01A-26 Engine — 1.8L/2.0L 303-01A-26

IN-VEHICLE REPAIR (Continued)

10. Remove the valve cover. 13. NOTE: Do not discard the crankshaft pulley
retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and re-
move the crankshaft pulley

11. Remove the accessory drive belt. For

additional information, refer to Section
303-05.
12. NOTE: Only turn the engine in the normal
direction of rotation. 14. Using the special tool, remove the
Turn the engine until piston No. 1 is ap- crankshaft front oil seal.
proximately 45 degrees before top dead • Discard the oil seal.
center (TDC).

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IN-VEHICLE REPAIR (Continued)

Installation
4. Lower the vehicle.
1. Measure the thickness of the crankshaft 5. NOTE: Only turn the engine in the normal
pulley retaining bolt washer. direction of rotation.
Using an open-ended wrench, carefully
turn the camshafts until the cams of
cylinder No. 4 are at valve overlap
position.
6. Install the special tool.

2. NOTE: If the thickness of the crankshaft pulley

retaining bolt washer is less then 5.5 mm, a
friction washer must be installed.
Install a friction washer to the crankshaft
(engine shown removed for clarity).
7. Raise and support the vehicle. For
additional information, refer to Section
100-02.
8. Remove the cylinder block lower blanking
plug and install the special tool.

3. NOTE: Install a new crankshaft front oil seal.

Using the special tools, install the crank-
shaft front oil seal.

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IN-VEHICLE REPAIR (Continued)

9. NOTE: Only turn the engine in the normal 12. NOTE: Install a new crankshaft pulley
direction of rotation. retaining bolt.
Using the crankshaft pulley retaining bolt, Using the special tools, prevent the
turn the engine until piston No. 1 is at TDC. crankshaft pulley from rotating and
tighten the crankshaft pulley retaining
bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
• Stage 2: 90 degrees.

10. Remove the crankshaft pulley retaining

bolt.
• Discard the bolt.
11. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
13. Remove the crankshaft pulley securing
Install the crankshaft pulley onto the bolt.
crankshaft and secure the crankshaft pul-
ley to the front cover using a M6 x 18 mm
bolt.

14. Lower the vehicle.

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IN-VEHICLE REPAIR (Continued)

15. Remove the special tool. 20. NOTE: Only turn the engine in the normal
direction of rotation.
Turn the engine until piston No. 1 is at
TDC.
21. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the valve timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

16. Raise and support the vehicle. For

additional information, refer to Section
100-02.
17. Remove the special tool.

22. Lower the vehicle.

23. NOTE: If it is not possible to install the
special tool, correct the valve timing.
Using the special tool, check the position
of the camshafts.

18. NOTE: Only turn the engine in the normal

direction of rotation.
Turn the engine two revolutions.
19. Install the special tool.

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IN-VEHICLE REPAIR (Continued)

24. Remove the special tool. 28. Install the cylinder block lower blanking
plug.

25. Raise and support the vehicle. For

additional information, refer to Section 29. Install the accessory drive belt. For
100-02. additional information, refer to Section
26. Remove the crankshaft pulley securing 303-05.
bolt. 30. Apply a small bead of silicon sealant to
the areas as shown.

27. Remove the special tool.

31. NOTE: Install a new valve cover gasket if
necessary.
Install the valve cover.
• Tighten the bolts in the sequence shown.

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IN-VEHICLE REPAIR (Continued)

32. Using the special tool, install the spark 35. Attach the PCV hose to the valve cover.
plugs.

36. Connect the CMP sensor electrical con-

33. Using the special tool, connect the spark nector.
plug electrical connectors.

37. Attach the engine wiring harness electri-

34. Install the engine upper cover retaining cal connector to the valve cover.
brackets.

38. Connect the battery ground cable. For

additional information, refer to Section
414-01.

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IN-VEHICLE REPAIR (Continued)

39. Install the engine upper cover.

40. Attach the PCV hose and the vacuum

hose to the engine upper cover.

41. Initialize the door window motors. For

additional information, refer to Section
501-11.

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IN-VEHICLE REPAIR

Valve Seals (21 238 0)

2. Using the special tool, apply 7 to 10 bar of
compressed air into the cylinder.
Special Tool(s)
Compressor, Valve Spring
303-361 (21-155)

Adapter for 303-361

303-361-02 (21-155-02A)

Installer, Valve Stem Collets 3. Remove the valve tappets and keep them
303-362 (21-156) in order for reassembly.
4. Using the special tools, remove the valve
springs.
• Compress the valve spring.
Adapter, Air Supply (Cylinder • Remove the valve collets.
Head) • Release the valve spring.
303-363 (21-157) • Remove the valve spring retainer and the
valve spring.

Pliers, Valve Stem Oil Seal

303-508 (21-165)

Removal
1. Remove the camshafts. For additional
information, refer to Camshafts in this
section.

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IN-VEHICLE REPAIR (Continued)

5. Using the special tools, remove the valve 2. Using the special tools, install the valve
seals. springs.
• Discard the valve seals. • Install the valve spring retainer and the
valve springs.
• Compress the valve spring.
• Install the valve collets.
• Release the valve spring.

Installation
1. NOTE: Install new valve seals.
NOTE: Cover the valve collet groove on the valve 3. Remove the special tools.
stem with a protective sleeve. 4. Install the valve tappets.
Using the special tools, install the valve 5. Install the camshafts. For additional
seals. information, refer to Camshafts in this
• Remove the protective sleeve. section.

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IN-VEHICLE REPAIR

Valves (21 215 4)

2. Using the special tools, remove the valve
springs.
• Compress the valve spring.
Special Tool(s)
• Remove the valve collets.
Compressor, Valve Spring • Release the valve spring.
303-361 (21-155) • Remove the valve spring retainer and the
valve spring.

Adapter for 303-361

303-361-02 (21-155-02A)

Installer, Valve Stem Collets

303-362 (21-156)

Pliers, Valve Stem Oil Seal 3. Using the special tool, remove the valve
303-508 (21-165) seals.
• Discard the valve seals.

Removal
1. Remove the cylinder head. For additional
information, refer to Cylinder Head in this
section.

4. Remove the valves.

Installation
1. Install the valves.

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303-01A-36 Engine — 1.8L/2.0L 303-01A-36

IN-VEHICLE REPAIR (Continued)

2. NOTE: Install new valve seals.
NOTE: Cover the valve collet groove on the valve
stem with a protective sleeve.
Using the special tool, install the valve
seals.
• Remove the protective sleeve.

3. Using the special tools, install the valve

springs.
• Install the valve spring retainer and the
valve spring.
• Compress the valve spring
• Install the valve collets.
• Release the valve spring.

4. Remove the special tools.

5. Install the cylinder head. For additional
information, refer to Cylinder Head in this
section.

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IN-VEHICLE REPAIR

Camshafts (21 284 0)

Removal
Special Tool(s)
1. Detach the positive crankcase ventilation
Flange Holding Wrench, hose (PCV) and the vacuum hose from the
Universal engine upper cover.
205-072 (15-030A)

Timing Plate, Camshaft

Alignment
303-376 (21-162B)

Remover/Installer, Spark
Plug
303-499 (21-202)

2. Remove the engine upper cover.

Timing Peg, Crankshaft TDC
303-507 (21-210)

Pliers, Valve Stem Oil Seal

303-508 (21-211)

General Equipment
M6 x 18 mm bolt 3. Disconnect the battery ground cable. For
additional information, refer to Section
M6 x 25 mm bolt 414-01.

Name Specification
Silicone sealant WSE-M4G323-A6
Sealant 3M 2510 ESS-M11P24-A1
Hypoid oil SQM-2C9002-AA

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303-01A-38 Engine — 1.8L/2.0L 303-01A-38

IN-VEHICLE REPAIR (Continued)

4. Disconnect the camshaft position (CMP) 7. Remove the engine upper cover retaining
sensor electrical connector. brackets.

5. Detach the engine wiring harness electri- 8. Using the special tool, disconnect the
cal connector from the valve cover. spark plug electrical connectors.

6. Detach the PCV hose from the valve cover. 9. Using the special tool, remove the spark
plugs.

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303-01A-39 Engine — 1.8L/2.0L 303-01A-39

IN-VEHICLE REPAIR (Continued)

10. Remove the valve cover. 15. Lower the vehicle.

16. Remove the engine front cover upper
blanking plug.

11. Remove the accessory drive belt. For

additional information, refer to Section
303-05.
12. Raise and support the vehicle. For
additional information, refer to Section
100-02.
13. Remove the engine front cover lower
blanking plug.

14. Remove the cylinder block lower blank-

ing plug and install the special tool.

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303-01A-40 Engine — 1.8L/2.0L 303-01A-40

IN-VEHICLE REPAIR (Continued)

17. CAUTION: To detension the timing 18. CAUTION: Hold the camshaft by the
chain, make sure the timing chain hexagon with an open-ended wrench
tensioner ratchet is in the released to stop it from turning.
position. NOTE: Using a suitable piece of wire, prevent the
Detension the timing chain. timing chain and the sprocket from dropping into
the timing case.
1. Using a suitable screwdriver, unlock the
timing chain tensioner ratchet. Loosen the camshaft sprockets retaining
2. Carefully turn the exhaust camshaft by the bolts.
hexagon in the normal direction of rotation, • Detach the exhaust camshaft sprocket to-
to detension the timing chain tensioner. gether with the timing chain from the ex-
3. Install a suitable M6 x 18 mm bolt through haust camshaft.
the blanking plug to secure the timing chain
guide in the detensioned position.

19. CAUTION: Keep the camshaft bearing

caps, the camshafts and the camshaft
sprockets in order for installation.
NOTE: Working in several stages, release each
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft bearing caps in the
sequence shown .

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303-01A-41 Engine — 1.8L/2.0L 303-01A-41

IN-VEHICLE REPAIR (Continued)

20. NOTE: Using a suitable piece of wire, prevent 3. CAUTION: Install the camshafts
the timing chain and the sprocket from approximately at valve overlap
dropping into the timing case. position cylinder No. 4.
Detach the intake camshaft sprocket from
CAUTION: Install the camshafts and
the intake camshaft.
bearing caps in their original location.
Install the camshafts.
Installation • Working in several stages, evenly tighten
the camshaft bearing cap bolts in the
1. Turn the engine against its normal direc-
sequence shown, one half turn at a time.
tion until piston No. 1 is approximately 45
degrees before top dead center (TDC). • Coat the camshaft bearing caps with
hypoid oil.
• Tighten the bolts in two stages:
• Stage 1: 7 Nm.
• Stage 2: 16 Nm.

2. NOTE: Do not tighten the camshaft sprocket

retaining bolt at this stage.
Attach the intake camshaft sprocket
together with the timing chain to the intake
camshaft and insert the intake camshaft. 4. NOTE: Do not tighten the camshaft sprocket
retaining bolt at this stage.
Attach the exhaust camshaft sprocket to-
gether with the timing chain to the exhaust
camshaft.

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IN-VEHICLE REPAIR (Continued)

5. Install the special tool. 9. NOTE: Hold the camshafts by the hexagon
with an open-ended wrench to stop them from
rotating.
Tighten the camshaft sprocket retaining
bolts.

6. Coat the engine front cover upper blanking

plug with sealant.
7. Tension the timing chain.
• Remove the timing chain guide securing
bolt and install the engine front cover upper 10. Remove the special tool.
blanking plug.

11. Raise and support the vehicle. For

8. NOTE: Only turn the engine in the normal additional information, refer to Section
direction of rotation. 100-02.
Turn the engine until piston No. 1 is at 12. Remove the special tool from the cylinder
TDC. block.

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IN-VEHICLE REPAIR (Continued)

13. NOTE: Only turn the engine in the normal 18. NOTE: If it is not possible to install the
direction of rotation. special tool, correct the valve timing.
Turn the engine two revolutions. Using the special tool, check the position
14. Install the special tool. of the camshafts.

15. NOTE: Only turn the engine in the normal 19. Remove the special tool.
direction of rotation.
Turn the engine until piston No. 1 is at
TDC.
16. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the valve timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

20. Raise and support the vehicle. For

additional information, refer to Section
100-02.
21. Remove the crankshaft pulley securing
bolt.

17. Lower the vehicle.

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IN-VEHICLE REPAIR (Continued)

22. Remove the special tool. 27. Apply a small bead of sealer to the areas
as shown.

23. Install the cylinder block lower blanking

plug. 28. NOTE: Install a new valve cover gasket if
necessary.
Install the valve cover.
• Tighten the bolts in the sequence shown.

24. Coat the engine front cover lower

blanking plug with sealant.
25. Install the engine front cover lower blank-
ing plug.
29. Using the special tool, install the spark
plugs.

26. Install the accessory drive belt. For

additional information, refer to Section
303-05.

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IN-VEHICLE REPAIR (Continued)

30. Using the special tool, connect the spark 33. Connect the CMP sensor electrical con-
plug electrical connectors. nector.

31. Install the engine upper cover retaining 34. Attach the engine wiring harness electri-
brackets. cal connector to the valve cover.

32. Attach the PCV hose to the valve cover. 35. Connect the battery ground cable. For
additional information, refer to Section
414-01.
36. Install the engine upper cover.

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303-01A-46 Engine — 1.8L/2.0L 303-01A-46

IN-VEHICLE REPAIR (Continued)

37. Attach the PCV hose and the vacuum
hose to the engine upper cover.

38. Initialize the door window motors. For

additional information, refer to Section
501-11.

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303-01A-47 Engine — 1.8L/2.0L 303-01A-47

IN-VEHICLE REPAIR

Timing Chain (21 314 0)

Name Specification
Loctite 7070
Special Tool(s) Silicone sealant WSE-M4G323-A6
Flange Holding Wrench,
Universal
205-072 (15-030A) Removal
1. Detach the positive crankcase ventilation
(PCV) hose and the vacuum hose from the
Adapter for 205-072 engine upper cover.
205-072-02 (15-030A-02)

Timing Plate, Camshaft

Alignment
303-376 (21-162B)

Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)
2. Remove the engine upper cover.

Remover/Installer, Spark
Plug
303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

Pliers, Valve Stem Oil Seal

303-508 (21-211) 3. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.

General Equipment
Trolley Jack
M6 x 18 mm bolt

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303-01A-48 Engine — 1.8L/2.0L 303-01A-48

IN-VEHICLE REPAIR (Continued)

4. Disconnect the camshaft position (CMP) 7. Remove the engine upper cover retaining
sensor electrical connector. brackets.

5. Detach the engine wiring harness electri- 8. Using the special tool, disconnect the
cal connector from the valve cover. spark plug electrical connectors.

6. Detach the PCV hose from the valve cover. 9. Using the special tool, remove the spark
plugs.

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303-01A-49 Engine — 1.8L/2.0L 303-01A-49

IN-VEHICLE REPAIR (Continued)

10. Remove the valve cover. 14. NOTE: Only turn the engine in the normal
direction of rotation.
Turn the engine until piston No. 1 is ap-
proximately 45 degrees before top dead
center (TDC).

11. Loosen the water pump pulley retaining

bolts by three turns.

15. NOTE: Do not discard the crankshaft pulley

retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and re-
move the crankshaft pulley.

12. Remove the power steering pump. For

additional information, refer to Section
211-02.
13. Raise and support the vehicle. For
additional information, refer to Section
100-02.

16. Remove the engine front cover lower

bolts.

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303-01A-50 Engine — 1.8L/2.0L 303-01A-50

IN-VEHICLE REPAIR (Continued)

21. Detach the coolant expansion tank and
17. Disconnect the crankshaft position (CKP)
position it to one side.
sensor electrical connector.

22. NOTE: Support the engine with wooden

18. Lower the vehicle.
blocks.
19. Remove the water pump pulley.
Position a trolley jack with the wooden
block under the oil pan and raise the
engine so that the engine front mount is
free from load.
23. Remove the engine front mount.

20. Using the special tool, disconnect the

coolant hose from the coolant expansion
tank.

24. Remove the accessory drive belt idler.

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IN-VEHICLE REPAIR (Continued)

25. Remove the engine front cover upper 27. NOTE: Hold the camshafts by the hexagon
retaining bolts. with an open-ended wrench to stop them from
• Remove the engine front cover. rotating.
Remove the camshaft sprockets and the
timing chain.

26. Detension the timing chain (engine

shown removed for clarity).
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide. Installation
3. Fix the timing chain tensioner with a suit-
able pin punch. 1. Clean the engine front cover mating faces
with Loctite 7070.
2. NOTE: Only turn the engine in the normal
direction of rotation.
Using an open-ended wrench, carefully
turn the camshafts until the cams of
cylinder No. 4 are at valve overlap
position.
3. Install the special tool.

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303-01A-52 Engine — 1.8L/2.0L 303-01A-52

IN-VEHICLE REPAIR (Continued)

4. CAUTION: Do not fully tighten the 6. CAUTION: Hold the camshafts by the
camshaft sprocket retaining bolts at hexagon with an open-ended wrench
this stage. Make sure the camshaft to stop them from rotating.
sprockets turn on the camshafts.
Tighten the camshaft sprocket retaining
Install both camshaft sprockets and the bolts.
timing chain.

7. NOTE: Install the engine front cover within 10

5. Tension the timing chain. minutes of applying the silicone sealant.
• Apply pressure to the timing chain ten- Apply a 3 mm bead of silicone sealant to
sioner and remove the securing pin. the engine front cover.

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303-01A-53 Engine — 1.8L/2.0L 303-01A-53

IN-VEHICLE REPAIR (Continued)

8. Install the engine front cover (engine 10. Install the engine front mount.
shown removed for clarity). • Lower the engine and transmission
• Tighten the bolts in the sequence shown. assembly.
• Bolts 1 through 8 to 10 Nm. • Install the engine front mount.
• Bolt 9: 48 Nm.
• Bolts 10 through 19 to 10 Nm.
• Bolts 20 through 22 to 48 Nm.

11. Remove the trolley jack.

12. Raise and support the vehicle. For
additional information, refer to Section
100-02.
13. Connect the CKP sensor electrical con-
nector.

9. Install the accessory drive belt idler.

14. Remove the cylinder block lower blank-

ing plug and install the special tool.

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303-01A-54 Engine — 1.8L/2.0L 303-01A-54

IN-VEHICLE REPAIR (Continued)

15. Measure the thickness of the crankshaft 18. Remove the crankshaft pulley retaining
pulley retaining bolt washer. bolt.
• Discard the bolt.
19. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
Install the crankshaft pulley onto the
crankshaft and secure the crankshaft pul-
ley to the front cover using a M6 x 18 mm
bolt.

16. NOTE: If the thickness of the crankshaft

pulley retaining bolt washer is less then 5.5
mm, a friction washer must be installed.
Install a friction washer to the crankshaft
(engine shown removed for clarity).

20. NOTE: Install a new crankshaft pulley

retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and
tighten the crankshaft pulley retaining
bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
• Stage 2: 90 degrees.

17. NOTE: Only turn the engine in the normal

direction of rotation.
Using the crankshaft pulley retaining
bolt, turn the engine until piston No. 1 is
at TDC.

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303-01A-55 Engine — 1.8L/2.0L 303-01A-55

IN-VEHICLE REPAIR (Continued)

21. Remove the crankshaft pulley securing 27. Install the special tool.
bolt.

28. NOTE: Only turn the engine in the normal

22. Lower the vehicle. direction of rotation.
23. Remove the special tool. Turn the engine until piston No. 1 is at
TDC.
29. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

24. Raise and support the vehicle. For

additional information, refer to Section
100-02.
25. Remove the special tool.

30. Lower the vehicle.

26. NOTE: Only turn the engine in the normal

direction of rotation.
Turn the engine two revolutions.

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303-01A-56 Engine — 1.8L/2.0L 303-01A-56

IN-VEHICLE REPAIR (Continued)

31. NOTE: If it is not possible to install the 35. Remove the special tool.
special tool, correct the engine timing.
Using the special tool, check the position
of the camshafts.

36. Install the cylinder block lower blanking

plug.

32. Remove the special tool.

37. Lower the vehicle.

38. Attach the coolant expansion tank.
33. Raise and support the vehicle. For
additional information, refer to Section
100-02.
34. Remove the crankshaft pulley securing
bolt.

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303-01A-57 Engine — 1.8L/2.0L 303-01A-57

IN-VEHICLE REPAIR (Continued)

39. Using the special tool, connect the cool- 43. Apply a small bead of silicone sealant to
ant hose to the coolant expansion tank. the areas as shown.

40. NOTE: Do not fully tighten the water pump 44. NOTE: Install a new valve cover gasket if
pulley retaining bolts at this stage. necessary.
Install the water pump pulley. Install the valve cover.
• Tighten the bolts in the sequence shown.

41. Install the power steering pump. For

additional information, refer to Section 45. Using the special tool, install the spark
211-02. plugs.
42. Tighten the water pump pulley retaining
bolts.

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IN-VEHICLE REPAIR (Continued)

46. Using the special tool, connect the spark 49. Connect the CMP sensor electrical con-
electrical connectors. nector.

47. Install the engine upper cover retaining 50. Attach the engine wiring harness electri-
brackets. cal connector to the valve cover.

48. Attach the PCV hose to the valve cover. 51. Connect the battery ground cable. For
additional information, refer to Section
414-01.
52. Install the engine upper cover.

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303-01A-59 Engine — 1.8L/2.0L 303-01A-59

IN-VEHICLE REPAIR (Continued)

53. Attach the PCV hose and the vacuum

hose to the engine upper cover.

54. Initialize the door window motors. For

additional information, refer to Section
501-11.

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303-01A-60 Engine — 1.8L/2.0L 303-01A-60

IN-VEHICLE REPAIR

Cylinder Head (21 163 0)

Name Specification
Loctite 7070
Special Tool(s) Hypoid oil SQM-2C9002-AA
Flange Holding Wrench, Silicone sealant WSE-M4G323-A6
Universal
205-072 (15-030A)
Removal
1. WARNING: Do not smoke or carry
Adapter for 205-072 lighted tobacco or open flame of any
205-072-02 (15-030A-02) type when working on or near any fuel
related components. Highly flammable
mixtures are always present and may
ignite. Failure to follow these
instructions may result in personal
Timing Plate, Camshaft injury.
Alignment
Drain the cooling system. For additional
303-376 (21-162B)
information, refer to Section 303-03.
2. Remove the intake manifold. For
additional information, refer to Intake
Remover/Installer, Cooling Manifold in this section.
Hose Clamp 3. Disconnect the camshaft position (CMP)
303-397 (24-003) sensor electrical connector.

Remover/Installer, Spark
Plug
303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

Pliers, Valve Stem Oil Seal

303-508 (21-211)

General Equipment
Trolley Jack
M6 x 18 mm bolt

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IN-VEHICLE REPAIR (Continued)

4. Detach the engine wiring harness electri- 7. Using the special tool, disconnect the
cal connector from the valve cover. spark plug electrical connectors.

5. Detach the PCV hose from the valve cover. 8. Using the special tool, remove the spark
plugs.

6. Remove the engine upper cover retaining

brackets. 9. Remove the valve cover.

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IN-VEHICLE REPAIR (Continued)

10. Loosen the water pump pulley retaining 14. NOTE: Only turn the engine in the normal
bolts by three turns. direction of rotation.
Turn the engine until piston No. 1 is ap-
proximately 45 degrees before top dead
center (TDC).

11. Remove the power steering pump. For

additional information, refer to Section
211-02.
12. Raise and support the vehicle. For 15. NOTE: Do not discard the crankshaft pulley
additional information, refer to Section retaining bolt.
100-02.
Using the special tools, prevent the
13. Disconnect the exhaust front pipe.
crankshaft pulley from rotating and re-
1. Remove the exhaust manifold heat shield move the crankshaft pulley.
lower retaining bolts.
2. Detach the exhaust manifold from the
retaining bracket.
3. Detach the exhaust front pipe from the ex-
haust manifold.

16. Remove the engine front cover lower re-

taining bolts.

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IN-VEHICLE REPAIR (Continued)

21. Remove the exhaust manifold upper heat

17. Disconnect the crankshaft position (CKP)
shield.
sensor electrical connector.

22. Detach the exhaust manifold retaining

18. Disconnect the heated oxygen sensor
bracket.
(HO2S) electrical connector.

23. Remove the generator upper retaining

19. Lower the vehicle.
bolt.
20. Using the special tool, disconnect the
coolant hoses.

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IN-VEHICLE REPAIR (Continued)

24. Detach the ground lead from the cylinder 27. Detach the coolant expansion tank and
head. position it to one side.

25. Remove the water pump pulley. 28. NOTE: Support the engine with suitable
wooden blocks.
Position a trolley jack with the wooden
block under the oil pan and raise the
engine so that the engine front mount is
free from load.
29. Remove the engine front mount.

26. Using the special tool, disconnect the

coolant hose from the coolant expansion
tank.

30. Remove the accessory drive belt idler.

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IN-VEHICLE REPAIR (Continued)

31. Remove the engine front cover upper 33. NOTE: Hold the camshafts by the hexagon
retaining bolts. with an open-ended wrench to prevent them
• Remove the engine front cover. from turning.
Remove the camshaft sprockets.
• Detach the timing chain from the camshaft
sprockets.

32. Detension the timing chain (engine

shown removed for clarity).
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide. 34. Remove the timing chain guides.
3. Fix the timing chain tensioner with a suit-
able pin punch.

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IN-VEHICLE REPAIR (Continued)

35. CAUTION: Keep the camshaft bearing 37. CAUTION: Remove the cylinder head
caps, valve tappets and the camshafts bolts in the sequence shown.
in order for installation.
Remove the cylinder head.
CAUTION: Remove the camshaft bearing • Discard the gasket.
caps in the sequence shown. • Discard the bolts.
NOTE: Working in several stages, release each
camshaft bearing cap retaining bolt two turns at a
time.
Remove the camshaft bearing caps.
• Remove the valve tappets.

Installation
1. Clean the engine front cover mating faces
with Loctite 7070.
36. Disconnect the fuel supply line. For addi- 2. Check the cylinder head for distortion. For
tional information, refer to Section 310- additional information, refer to Section
00. 303-00.
3. NOTE: Install new cylinder head bolts and
gasket.
Install the cylinder head.
• Tighten the cylinder head bolts in the
sequence shown in five stages:
• Stage 1: 5 Nm.
• Stage 2: 15 Nm.
• Stage 3: 45 Nm.
• Stage 4: 90 degrees.
• Stage 5: 90 degrees.

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IN-VEHICLE REPAIR (Continued)

8. Install the special tool.

4. Connect the fuel supply line. For addi-
tional information, refer to Section 310-00.

9. Install the timing chain guides.

5. Install the valve tappets.
6. CAUTION: Working in several stages,
evenly tighten the camshaft bearing
cap bolts in the sequence shown, one
half turn at a time.
Install the camshafts.
• Coat the camshaft bearing caps with
hypoid oil.
• Tighten the bolts in the sequence shown in
two stages:
• Stage 1: 7 Nm
• Stage 2: 16 Nm
10. CAUTION: Do not fully tighten the
camshaft sprocket retaining bolts at
this stage. Make sure the camshaft
sprockets turn on the camshafts.
Install the camshaft sprockets.
• Install the timing chain.

7. NOTE: Only turn the engine in the normal

direction of rotation.
Using an open-ended wrench, carefully
turn the camshafts until the cams of
cylinder No. 4 are at valve overlap
position.

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IN-VEHICLE REPAIR (Continued)

11. Tension the timing chain. 13. NOTE: Install the front cover within 10
• Apply pressure to the timing chain ten- minutes of applying the silicone sealant.
sioner, and remove the securing pin. Apply a 3 mm bead of silicone sealant to
the front cover.

12. CAUTION: Hold the camshafts by the

hexagon with an open-ended wrench
to prevent them from turning.
Tighten the camshaft sprocket retaining
bolts.

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IN-VEHICLE REPAIR (Continued)

14. Install the engine front cover (engine 16. Install the engine front mount.
shown removed for clarity).
• Tighten the bolts in the sequence shown:
• Bolts 1 through 8 to 10 Nm.
• Bolt 9: 48 Nm.
• Bolts 10 through 19 to 10 Nm.
• Bolts 20 through 22 to 48 Nm.

17. Remove the trolley jack.

18. Raise and support the vehicle. For
additional information, refer to Section
100-02.
19. Connect the CKP sensor electrical con-
nector.

15. Install the accessory drive belt idler. 20. Remove the cylinder block lower blank-
ing plug and install the special tool.

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IN-VEHICLE REPAIR (Continued)

21. Measure the thickness of the crankshaft
24. Remove the crankshaft pulley retaining
pulley retaining bolt washer.
bolt.
• Discard the bolt.
25. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
Install the crankshaft pulley onto the
crankshaft and secure the crankshaft pul-
ley to the front cover using a M6 x 18 mm
bolt.

22. NOTE: If the thickness of the crankshaft

pulley retaining bolt washer is less then 5.5
mm, a friction washer must be installed.
Install a friction washer to the crankshaft
(engine shown removed for clarity).

26. NOTE: Install a new crankshaft pulley

retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and
tighten the crankshaft pulley retaining
bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
• Stage 2: 90 degrees.

23. NOTE: Only turn the engine in the normal

direction of rotation.
Using the crankshaft pulley retaining
bolt, turn the engine until piston No. 1 is
at TDC.

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IN-VEHICLE REPAIR (Continued)

27. Remove the crankshaft pulley securing 33. Install the special tool.
bolt.

34. NOTE: Only turn the engine in the normal

28. Lower the vehicle. direction of rotation.
29. Remove the special tool. Turn the engine until piston No. 1 is at
TDC.
35. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

30. Raise and support the vehicle. For

additional information, refer to Section
100-02.
31. Remove the special tool.

36. Lower the vehicle.

32. NOTE: Only turn the engine in the normal

direction of rotation.
Turn the engine two revolutions.

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IN-VEHICLE REPAIR (Continued)

37. NOTE: If it is not possible to install the 41. Remove the special tool.
special tool, correct the engine timing.
Using the special tool, check the position
of the camshafts.

42. Install the cylinder block lower blanking

plug.

38. Remove the special tool.

43. Connect the HO2S sensor electrical con-

nector.
39. Raise and support the vehicle. For
additional information, refer to Section
100-02.
40. Remove the crankshaft pulley securing
bolt.

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IN-VEHICLE REPAIR (Continued)

44. Connect the exhaust front pipe. 48. NOTE: Do not fully tighten the water pump
1. Attach the exhaust front pipe to the pulley retaining bolts at this stage.
exhaust manifold. Install the water pump pulley.
2. Attach the exhaust manifold to the retaining
bracket.
3. Install the exhaust manifold heat shield
lower retaining bolts.

49. Attach the ground lead to the cylinder

head.

45. Lower the vehicle.

46. Attach the coolant expansion tank.

50. Install the generator upper retaining bolt.

47. Using the special tool, connect the cool-

ant hose to the coolant expansion tank.

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IN-VEHICLE REPAIR (Continued)

51. Attach the exhaust manifold bracket. 55. Tighten the water pump pulley retaining
bolts.

52. Install the exhaust manifold upper heat

shield. 56. Apply a small bead of silicone sealant to
the areas as shown.

53. Using the special tool, connect the cool-

ant hoses. 57. NOTE: Install a new valve cover gasket if
necessary.
Install the valve cover.
• Tighten the bolts in the sequence shown.

54. Install the power steering pump. For

additional information, refer to Section
211-02.

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IN-VEHICLE REPAIR (Continued)

58. Using the special tool, install the spark 61. Attach the PCV hose to the valve cover.
plugs.

62. Connect the CMP sensor electrical con-

59. Using the special tool, connect the spark nector.
plug electrical connectors.

63. Attach the engine wiring harness electri-

60. Install the engine upper cover retaining cal connector to the valve cover.
brackets.

64. Install the intake manifold. For

additional information, refer to Intake
Manifold in this section.
65. Fill and bleed the cooling system. For
additional information, refer to Section
303-03.

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IN-VEHICLE REPAIR (Continued)

66. Fill and bleed the power steering system.
For additional information, refer to
Section 211-02.
67. Initialize the door window motors. For
additional information, refer to Section
501-11.

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IN-VEHICLE REPAIR

Oil Pan (21 154 0)

Special Tool(s)
Remover/Installer, Cooling
Special Tool(s) Hose Clamp
303-397 (24-003)
Flange Holding Wrench,
Universal
205-072 (15-030A)
Separator, Oil Pan
303-428 (21-179)
Adapter for 205-072
205-072-02 (15-030A-02)

Remover/Installer, Spark
Plug
303-499 (21-202)
Support Bar, Engine
303-290 (21-140)

Timing Peg, Crankshaft TDC

303-507 (21-210)
Adapter for 303-290 (21-140)
303-290-01 (21-140-01)

Pliers, Valve Stem Oil Seal

303-508 (21-211)
Adapter for 303-290 (21-140)
303-290-02 (21-140-02)

General Equipment

Adapter for 303-290 (21-140) Trolley Jack

303-290-03 (21-140-03) M6 x 18 mm bolt

Name Specification
Loctite 7070
Adapter for 303-290 (21-140)
Engine oil WSS-M2C913-A
303-290-05A (21-140-05A)
Silicone sealant WSE-M4G323-A6

Timing Plate, Camshaft

Alignment
303-376 (21-162B)

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IN-VEHICLE REPAIR (Continued)

Removal 5. Detach the engine wiring harness electri-
cal connector from the valve cover.
1. Detach the positive crankcase ventilation
(PCV) hose and the vacuum hose from the
engine upper cover.

6. Detach the PCV hose from the valve cover.

2. Remove the engine upper cover.

7. Remove the engine upper cover brackets.

3. Disconnect the battery ground cable. For

additional information, refer to Section
414-01.
4. Disconnect the camshaft position sensor
(CMP) sensor electrical connector.

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IN-VEHICLE REPAIR (Continued)

8. Using the special tool, disconnect the 11. Loosen the water pump pulley retaining
spark plug electrical connectors. bolts by three turns.

9. Using the special tool, remove the spark 12. Remove the power steering pump. For
plugs. additional information, refer to Section
211-02.
13. Raise and support the vehicle. For
additional information, refer to Section
100-02.
14. NOTE: Only turn the engine in the normal
direction of rotation.
Turn the engine until piston No. 1 is ap-
proximately 45 degrees before top dead
center (TDC).

10. Remove the valve cover.

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IN-VEHICLE REPAIR (Continued)

15. NOTE: Do not discard the crankshaft pulley 19. Remove the water pump pulley.
retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and re-
move the crankshaft pulley.

20. Using the special tool, disconnect the

coolant hose from the coolant expansion
tank.

16. Remove the engine front cover lower re-

taining bolts.

21. Detach the coolant expansion tank and

position it to one side.

17. Disconnect the crankshaft position (CKP)

sensor electrical connector.

22. NOTE: Support the engine with wooden

blocks.
Position a trolley jack with the wooden
18. Lower the vehicle. block under the oil pan and raise the

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IN-VEHICLE REPAIR (Continued)

engine so that the engine front mount is 26. Install the special tools.
free from load.
23. Remove the engine front mount.

27. Raise and support the vehicle. For

additional information, refer to Section
24. Remove the accessory drive belt idler. 100-02.
28. NOTE: Inspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required.
Drain the engine oil.
• Allow the oil to drain into a suitable
container.
• Install the drain plug.

25. Remove the engine front cover upper

retaining bolts.
• Remove the engine front cover.

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IN-VEHICLE REPAIR (Continued)

29. Remove the transaxle lower retaining 2. NOTE: Install the oil pan within 10 minutes of
bolts. applying the silicone sealant and tighten the
retaining bolts within a further 5 minutes.
Apply a 3 mm bead of silicone sealant to
the oil pan.

30. Remove the oil pan retaining bolts.

3. NOTE: Do not tighten the retaining bolts at this

stage.
Install the oil pan.

31. Using the special tool, remove the oil

pan.

4. Using a suitable straight edge, align the oil

pan to the cylinder block mating face on
the timing chain side.

Installation
1. Using Loctite 7070, clean the engine
cylinder block and oil pan mating faces.

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IN-VEHICLE REPAIR (Continued)

5. Tighten the oil pan retaining bolts in the 11. NOTE: Install the engine front cover within 10
sequence shown. minutes of applying the silicone sealer.
Apply a 3 mm bead of silicone sealer to
the front cover.

6. Install the transaxle lower retaining bolts.

7. Lower the vehicle.

8. NOTE: Support the engine with wooden
blocks.
Using a trolley jack, support the engine
and transmission assembly.
9. Remove the special tools.

10. Clean the engine front cover mating faces

with Loctite 7070.

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IN-VEHICLE REPAIR (Continued)

12. Install the engine front cover (engine 14. Install the engine front mount.
shown removed for clarity). • Lower the engine and transmission
• Tighten the bolts in the sequence shown. assembly.
• Bolts 1 through 8 to 10 Nm. • Install the engine front mount.
• Bolt 9: 48 Nm.
• Bolts 10 through 19 to 10 Nm.
• Bolts 20 through 22 to 48 Nm.

15. Install the special tool.

16. Remove the trolley jack.

17. Raise and support the vehicle. For
13. Install the accessory drive belt idler. additional information, refer to Section
100-02.
18. Install the transaxle lower retaining bolts.

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IN-VEHICLE REPAIR (Continued)

19. Connect the CKP sensor electrical con- 22. NOTE: If the thickness of the crankshaft
nector. pulley retaining bolt washer is less then 5.5
mm, a friction washer must be installed.
Install a friction washer to the crankshaft
(engine shown removed for clarity).

20. Remove the cylinder block lower blank-

ing plug and install the special tool.

23. NOTE: Only turn the engine in the normal

direction of rotation.
Using the crankshaft pulley retaining
bolt, turn the engine until piston No. 1 is
at TDC.

21. Measure the thickness of the crankshaft

pulley retaining bolt washer.

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IN-VEHICLE REPAIR (Continued)

24. Remove the crankshaft pulley retaining 27. Remove the crankshaft pulley securing
bolt. bolt.
• Discard the bolt.
25. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
Install the crankshaft pulley onto the
crankshaft and secure the crankshaft pul-
ley to the front cover using a M6 x 18 mm
bolt.

28. Lower the vehicle.

29. Remove the special tool.

26. NOTE: Install a new crankshaft pulley

retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and
tighten the crankshaft pulley retaining
bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
30. Raise and support the vehicle. For
• Stage 2: 90 degrees.
additional information, refer to Section
100-02.
31. Remove the special tool from the cylinder
block.

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IN-VEHICLE REPAIR (Continued)

32. NOTE: Only turn the engine in the normal 37. NOTE: If it is not possible to install the
direction of rotation. special tool, correct the engine timing.
Turn the engine two revolutions. Using the special tool, check the position
33. Install the special tool. of the camshafts.

34. NOTE: Only turn the engine in the normal 38. Remove the special tool.
direction of rotation.
Turn the engine until piston No. 1 is at
TDC.
35. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

39. Raise and support the vehicle. For

additional information, refer to Section
100-02.
40. Remove the crankshaft pulley securing
bolt.

36. Lower the vehicle.

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IN-VEHICLE REPAIR (Continued)

41. Remove the special tool. 45. Using the special tool, connect the cool-
ant hose to the coolant expansion tank.

42. Install the cylinder block lower blanking

plug. 46. NOTE: Do not fully tighten the water pump
pulley retaining bolts at this stage.
Install the water pump pulley.

43. Lower the vehicle.

44. Attach the coolant expansion tank.
47. Install the power steering pump. For
additional information, refer to Section
211-02.
48. Tighten the water pump pulley retaining
bolts.

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IN-VEHICLE REPAIR (Continued)

49. Apply a small bead of silicone sealant to 52. Using the special tool, connect the spark
the areas as shown. plug electrical connectors.

50. NOTE: Install a new valve cover gasket if 53. Install the engine upper cover retaining
necessary. brackets.
Install the valve cover.
• Tighten the bolts in the sequence shown.

54. Attach the PCV hose to the valve cover.

51. Using the special tool, install the spark

plugs.

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IN-VEHICLE REPAIR (Continued)

55. Connect the CMP sensor electrical con- 59. Attach the PCV hose and the vacuum
nector. hose to the engine upper cover.

56. Attach the engine wiring harness electri- 60. Fill the engine with engine oil.
cal connector to the valve cover. 61. Initialize the door window motors. For
additional information, refer to Section
501-11.

57. Connect the battery ground cable. For

additional information, refer to Section
414-01.
58. Install the engine upper cover.

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IN-VEHICLE REPAIR

Oil Pump (21 714 0)

5. Using the special tool, loosen the oil pump
sprocket retaining bolt.
Special Tool(s)
Flange Holding Wrench,
Universal
205-072 (15-030A)

Removal
1. Remove the timing chain. For additional
information, refer to Timing Chain in this
section.
2. Remove the oil pan. For additional 6. Remove the oil pump chain.
information, refer to Oil Pan in this section. 1. Remove the oil pump sprocket retaining
3. Remove the oil pump chain guide. bolt.
2. Remove the oil pump chain and the oil
pump sprocket.

4. Remove the oil pump chain tensioner.

7. Remove the oil pump.

• Discard the gasket.

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IN-VEHICLE REPAIR (Continued)

Installation 3. Using the special tool, tighten the oil pump
sprocket retaining bolt.
1. NOTE: Install a new oil pump gasket.
Install the oil pump.
• Tighten the bolts in the sequence shown in
two stages.
• Stage 1: 10 Nm.
• Stage 2: 23 Nm.

4. Install the oil pump chain tensioner.

2. Install the oil pump chain.

1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.

5. Install the oil pump chain guide.

6. Install the oil pan. For additional

information, refer to Oil Pan in this section.
7. Install the timing chain. For additional
information, refer to Timing Chain in this
section.

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IN-VEHICLE REPAIR

Crankshaft Rear Seal (21 468 4)

6. Remove the crankshaft rear oil seal carrier.
• Discard the crankshaft rear oil seal carrier.
Special Tool(s)
Locking Tool, Flywheel
303–254 (21–135)

Removal
1. Remove the oil pan. For additional
information, refer to Oil Pan in this section.
2. Remove the clutch disc and pressure
plate.
3. Using the special tool, lock the flywheel in Installation
position.
1. NOTE: Install a new crankshaft rear oil seal
carrier.
Install the crankshaft rear oil seal carrier.
• Tighten the retaining bolts in the sequence
shown.

4. Remove the flywheel.

• Discard the bolts.

5. Remove the special tool.

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IN-VEHICLE REPAIR (Continued)

2. NOTE: Install new flywheel bolts. 5. Remove the special tool.
Install the flywheel. 6. Install the clutch disc and pressure plate.
7. Install the oil pan. For additional
information, refer to Oil Pan in this section.

3. Using the special tool, lock the flywheel in

position.

4. Tighten the flywheel bolts.

• Tighten the bolts in the sequence shown in
three stages.
• Stage 1: 50 Nm.
• Stage 2: 80 Nm.
• Stage 3: 112 Nm.

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303-01A-95 Engine — 1.8L/2.0L 303-01A-95

REMOVAL

Engine — Vehicles With: Automatic Transaxle

REMOVAL

Removal
Special Tool(s)
All vehicles
Lifting Bracket, Engine
303-122 (21-068A) 1. 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
Remover/Installer, Cooling ignite. Failure to follow these
Hose Clamp instructions may result in personal
303-397 (24-003) injury.
Detach the positive crankcase ventilation
(PCV) hose and the vacuum hose from the
engine upper cover.
Remover, Halfshaft
308-256 (16-089)

General Equipment
Workshop Table
Engine Hoist

2. Remove the engine upper cover.

3. Disconnect the battery ground cable. For

additional information, refer to Section
414-01.

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303-01A-96 Engine — 1.8L/2.0L 303-01A-96

REMOVAL (Continued)
4. Remove the strut and spring assembly top 8. Detach the accelerator cable from the
mount brace cover on both sides. retaining bracket and position it to one
side.
1. Detach the inner cable from the throttle
body.
2. Turn the cable out of the bracket.

5. Loosen the strut and spring assembly top

mount retaining nuts by four turns on both
sides.

Vehicles with speed control

9. Detach the speed control cable from the
retaining bracket and position it to one
side.
1. Detach the speed control cable retaining
bracket from the throttle body.
2. Detach the inner cable from the throttle
body.

6. Drain the cooling system. For additional

information, refer to Section 303-03.
7. Remove the air cleaner housing.
1. Detach the hose clamp from the air cleaner
outlet pipe.
2. Disconnect the PCV hose.

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303-01A-97 Engine — 1.8L/2.0L 303-01A-97

REMOVAL (Continued)

All vehicles 13. Detach the power steering line bracket

10. Disconnect the wiring harness electrical from the valve cover.
connectors.

14. Using the special tool, disconnect the

11. Disconnect the engine wiring harness. coolant hoses.
• Remove the clip.

15. Using the special tool, disconnect the

12. Disconnect the generator electrical con- coolant hose from the expansion tank.
nectors. • Remove the clip.

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303-01A-98 Engine — 1.8L/2.0L 303-01A-98

REMOVAL (Continued)
16. Detach the coolant expansion tank from 19. Remove the cooling fan motor and
the wheel housing and position it to one shroud.
side. 1. Disconnect the electrical connectors.
2. Remove the nut on both sides (left-hand
side shown).

17. Disconnect the fuel supply line. For addi-

tional information, refer to Section 310-
00.
20. Disconnect the transmission range (TR)
sensor electrical connector.

18. Disconnect the vacuum hoses.

21. Disconnect the automatic transmission
control electrical connector.
• Remove the wiring harness retaining clip.
• Remove the cable ties.

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303-01A-99 Engine — 1.8L/2.0L 303-01A-99

REMOVAL (Continued)

22. Disconnect the heated oxygen (HO2S) 26. Disconnect the output shaft speed (OSS)
sensor electrical connector. sensor electrical connector.

23. Disconnect the ground cable from the 27. CAUTION: Support the halfshaft. The
transaxle. inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
NOTE: Plug the transaxle to prevent oil loss or
dirt ingress.
Using the special tool, detach the left-
hand halfshaft from the transaxle and
secure it to one side.
• Discard the snap ring.

24. Remove the subframe. For additional

information, refer to Section 502-00.
25. Disconnect the wiring harness electrical
connectors.

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303-01A-100 Engine — 1.8L/2.0L 303-01A-100

REMOVAL (Continued)

28. CAUTION: Support the halfshaft. The 31. CAUTION: Prevent the fluid pipe
inner joint must not be bent more than adapter from turning using an open-
18 degrees. The outer joint must not ended wrench, do not remove it from
be bent more than 45 degrees. the transaxle housing.
NOTE: Plug the fluid cooler openings to prevent
CAUTION: Do not damage the halfshaft
oil loss or dirt ingress.
oil seal.
NOTE: Plug the transaxle to prevent oil loss or Detach the fluid cooler pipe from the
dirt ingress. transaxle.
• Detach the fluid pipe bracket from the
Detach the right-hand halfshaft and the
transaxle.
intermediate shaft from the transaxle and
secure it to one side.
• Remove and discard the center bearing
cap and locknuts.

32. Disconnect the turbine shaft speed (TSS)

sensor electrical connector.
• Remove the cable retaining clip.
29. Remove the accessory drive belt. For
additional information, refer to Section
303-05.
30. Disconnect the crankshaft position (CKP)
sensor electrical connector.

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303-01A-101 Engine — 1.8L/2.0L 303-01A-101

REMOVAL (Continued)

33. CAUTION: Prevent the fluid pipe 35. Using the special tool, disconnect the
adapter from turning using an open- coolant hose from the radiator.
ended wrench, do not remove it from
the transaxle housing.
NOTE: Plug the fluid cooler openings to prevent
oil loss or dirt ingress.
Detach the fluid cooler return pipe from
the transaxle.

36. Disconnect the wiring harness.

34. CAUTION: Support the air

conditioning (A/C) compressor before
removing the retaining bolts and
secure it to prevent load being placed
on the refrigerant lines.
Detach the A/C compressor from the
mounting bracket and secure it to one
side.
37. Lower the vehicle.
38. Remove the engine wiring harness sup-
port bracket.

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303-01A-102 Engine — 1.8L/2.0L 303-01A-102

REMOVAL (Continued)
39. Disconnect the power steering hose from 41. Remove the power steering line support
the power steering fluid reservoir. retaining nut.
• Allow the fluid to drain into a suitable con-
tainer.

42. Remove the power steering pump pulley.

For additional information, refer to
40. NOTE: The power steering fluid reservoir Section 211-02.
contains a filter. If the power steering fluid is 43. Disconnect the power steering line from
contaminated a new power steering fluid the power steering pump.
reservoir must be installed.
Remove the power steering fluid
reservoir.
1. Remove the rear retaining stud.
2. Remove the front retaining bolts.
• Discard the O-ring seals.

44. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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303-01A-103 Engine — 1.8L/2.0L 303-01A-103

REMOVAL (Continued)

45. Position the workshop table under the 48. Remove the engine rear mount retaining
vehicle and carefully lower the vehicle, nut.
until the engine and transaxle assembly • Discard the nut.
is in the correct position to remove the
engine mounts.

49. Raise and support the vehicle and

remove the engine and transaxle
46. CAUTION: Do not support the oil pan. assembly. For additional information,
NOTE: Using suitable securing straps, secure the refer to Section 100-02.
engine and the transaxle on a workshop table. 50. Using a suitable engine hoist support the
engine and transaxle assembly and re-
Using suitable wooden blocks, support
move the securing straps.
the engine and transaxle assembly.

51. Remove the wiring harness retaining

47. Remove the engine front mount.
bracket.

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303-01A-104 Engine — 1.8L/2.0L 303-01A-104

REMOVAL (Continued)
52. Remove the starter motor. 55. Remove the transaxle lower retaining
• Detach the wiring harness from the retain- bolts.
ing bracket.

56. Remove the transaxle right-hand retain-

53. Remove the rubber cover and the four ing bolts.
torque converter retaining nuts.
• Rotate the engine to gain access to the
nuts.
• Discard the nuts.

57. Remove the transaxle left-hand retaining

bolts.

54. Remove the transaxle upper retaining

bolts.

58. CAUTION: Make sure that the torque

converter remains in the transaxle.
Remove the transaxle from the engine.

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303-01A-105 Engine — 1.8L/2.0L 303-01A-105

DISASSEMBLY

Engine (21 134 8)

DISASSEMBLY

1. Using the special tools, mount the engine

to the mounting stand.

Special Tool(s)
Flange Holding Wrench,
Universal
205-072 (15-030A)

Adaptor for 205-072

205-072-02 (15-030A-02)

Remover/Installer, Cooling 2. Remove the special tool.

Hose Clamp
303-397 (24-003)

Mounting Plate for 303-435-

06
303-435-11 (21-146C)

Mounting Bracket for 303-

435
303-435-06 (21-031B)
3. Remove the exhaust manifold.
• Discard the gasket.
Mounting Stand
303-435 (21-187)

Pliers, Valve Stem Oil Seal

303-508 (21-211)

Lifting Bracket, Engine

303-122 (21-068A)

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303-01A-106 Engine — 1.8L/2.0L 303-01A-106

DISASSEMBLY (Continued)
4. Remove the oil level indicator tube. 7. Using the special tool, disconnect the
coolant hoses.

5. Remove the intake manifold.

8. Remove the power steering pump.

6. Disconnect the positive crankcase ventila-

tion hose (PCV) from the intake manifold. 9. Using the special tool, disconnect the
spark plug electrical connectors.

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303-01A-107 Engine — 1.8L/2.0L 303-01A-107

DISASSEMBLY (Continued)

10. Remove the valve cover. 13. Using the special tools, prevent the
crankshaft pulley from rotating and re-
move the crankshaft pulley.

11. Remove the accessory drive belt idler

pulley.
14. Remove the engine front cover.

12. Remove the water pump pulley.

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303-01A-108 Engine — 1.8L/2.0L 303-01A-108

DISASSEMBLY (Continued)
15. Detension the timing chain. 18. Remove the chain tensioner.
1. Unlock the timing chain tensioner ratchet.
2. Apply pressure to the timing chain guide.
3. Fix the timing chain tensioner with a suit-
able pin punch.

19. Remove the oil pump chain guide.

16. NOTE: Hold each camshaft by the hexagon

with an open-ended wrench to stop it from
turning.
Remove the camshaft sprockets and the
timing chain.

20. Remove the oil pump chain tensioner.

17. Remove the chain guides.

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303-01A-109 Engine — 1.8L/2.0L 303-01A-109

DISASSEMBLY (Continued)

21. Using the special tool, loosen the oil 24. Remove the crankshaft sprocket.
pump sprocket retaining bolt.

25. Remove the rear friction washer (if

22. Remove the oil pump chain. equipped).
1. Remove the oil pump sprocket retaining
bolt.
2. Remove the oil pump chain and the oil
pump sprocket.

26. CAUTION: Remove the camshaft

bearing caps in the sequence shown.
NOTE: Working in several stages, release each
camshaft bearing cap retaining bolt two turns at a
23. Remove the front friction washer (if time.
equipped).
Remove the camshaft bearing caps.
• Remove the camshafts.
• Remove the valve tappets.

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303-01A-110 Engine — 1.8L/2.0L 303-01A-110

DISASSEMBLY (Continued)

27. CAUTION: Remove the cylinder head 30. Remove the knock sensor (KS).
bolts in the sequence shown.
Remove the cylinder head.
• Discard the gasket.

31. Remove the crankcase ventilation oil

separator.

28. Remove the water pump.

• Discard the O-ring.

32. Remove the oil filter adaptor.

• Discard the gasket.

29. Remove the thermostat housing.

• Discard the gasket.

33. Remove the clutch disc and pressure

plate.

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303-01A-111 Engine — 1.8L/2.0L 303-01A-111

DISASSEMBLY (Continued)

34. Using the special tool, lock the flywheel 37. NOTE: Inspect the oil pan drain plug seal for
in position. damage. Install a new drain plug and seal if
required.
Drain the engine oil.
• Allow the oil to drain into a suitable
container.
• Install the drain plug.

35. Remove the flywheel.

• Discard the bolts.

38. NOTE: Remove the oil pan by pulling it

downwards to prevent oil deposits or abraded
particles from entering the engine.
Remove the oil pan.

36. Remove the special tool.

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303-01A-112 Engine — 1.8L/2.0L 303-01A-112

DISASSEMBLY (Continued)
39. Remove the crankshaft rear oil seal
carrier.
• Discard the oil seal carrier.

40. Remove the oil pump.

• Discard the gasket.

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303-01A-113 Engine — 1.8L/2.0L 303-01A-113

ASSEMBLY

Engine (21 134 8)

ASSEMBLY

Name Specification
Silicone sealant WSE-M4G323-A6
Special Tool(s) Hypoid oil SQM-2C9002-AA
Flange holding wrench, Loctite7070
universal
205-072 (15-030A)
Assembly
1. NOTE: Install a new oil pump gasket.
Adaptor for 205-072
205-072-02 (15-030A-02) Install the oil pump.
• Tighten the bolts in the sequence shown in
two stages.
• Stage 1: 10 Nm.
• Stage 2: 23 Nm.
Lifting Bracket, Engine
303-122 (21-068A)

Timing Plate, Camshaft

Alignment
303-376 (21-162B)

Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)
2. NOTE: Install a new crankshaft rear oil seal
carrier.
Install the crankshaft rear oil seal carrier.
Timing Peg, Crankshaft TDC
• Tighten the bolts in the sequence shown.
303-507 (21-210)

Pliers, Valve Stem Oil Seal

303-508 (21-211)

General Equipment
Engine hoist
M6 x 18 mm bolt 3. Using Loctite 7070, clean the engine
Straight edge cylinder block and oil pan mating faces.

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303-01A-114 Engine — 1.8L/2.0L 303-01A-114

ASSEMBLY (Continued)
4. NOTE: Install the oil pan within 10 minutes of
8. Using the special tool, lock the flywheel in
applying the sealer and tighten the retaining
position.
bolts within a further 5 minutes.
Apply a 3 mm bead of sealant to the oil
pan.

9. Tighten the flywheel bolts.

• Tighten the bolts in the sequence shown in
three stages.
5. Using a suitable straight edge, align the oil
• Stage 1: 50 Nm.
pan to the cylinder block mating face on
the timing chain side. • Stage 2: 80 Nm.
6. Tighten the oil pan retaining bolts. • Stage 3: 112 Nm.
• Tighten the bolts in the sequence shown.

10. Remove the special tool.

7. NOTE: Install new flywheel bolts.
Install the flywheel.

11. Install the clutch disc and pressure plate.

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303-01A-115 Engine — 1.8L/2.0L 303-01A-115

ASSEMBLY (Continued)

12. NOTE: Install a new oil filter adaptor gasket. 15. NOTE: Install a new thermostat housing
gasket.
Install the oil filter adaptor.
Install the thermostat housing.

13. Install the positive crankcase ventilation

oil separator. 16. NOTE: Install a new water pump O-ring.
Install the water pump.

14. NOTE: Rotate the KS sensor as far counter-

clockwise as possible without touching the
PCV housing.
Install the knock sensor (KS).

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303-01A-116 Engine — 1.8L/2.0L 303-01A-116

ASSEMBLY (Continued)

17. NOTE: Install new cylinder head bolts and 20. CAUTION: Install the camshafts
gasket. approximately at valve overlap
Install the cylinder head. position cylinder No. 4.
• Tighten the cylinder head bolts in five Install the camshafts.
stages. • Working in several stages, evenly tighten
• 1. Stage: 5 Nm. the camshaft bearing cap bolts in the
• 2. Stage: 15 Nm. sequence shown, one half turn at a time.
• 3. Stage: 45 Nm. • Coat the camshaft bearing caps with
• 4. Stage: 90 degrees. hypoid oil.
• 5. Stage: 90 degrees. • Tighten the bolts in two stages.
• Stage 1: 7 Nm.
• Stage 2: 16 Nm.

18. NOTE: Only turn the engine in its normal

direction of rotation.
Turn the engine until piston No. 1 is ap- 21. Install the special tool.
proximately 45 degrees before top dead
center (TDC).

19. Install the valve tappets.

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303-01A-117 Engine — 1.8L/2.0L 303-01A-117

ASSEMBLY (Continued)

22. Install the rear friction washer. 25. Install the oil pump chain.
1. Install the oil pump chain and the oil pump
sprocket.
2. Install the oil pump sprocket retaining bolt.

23. Install the crankshaft sprocket.

26. Using the special tool, tighten the oil

pump sprocket retaining bolt.

24. Install the front friction washer.

27. Install the oil pump chain tensioner.

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303-01A-118 Engine — 1.8L/2.0L 303-01A-118

ASSEMBLY (Continued)

28. Install the oil pump chain guide. 31. CAUTION: Do not fully tighten the
camshaft sprocket retaining bolts at
this stage. Make sure the camshaft
sprockets turn on the camshafts.
Install the camshaft sprockets.
• Install the timing chain.

29. Install the timing chain tensioner.

32. Tension the timing chain.

• Apply pressure to the timing chain and re-
move the securing pin.

30. Install the timing chain guides.

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303-01A-119 Engine — 1.8L/2.0L 303-01A-119

ASSEMBLY (Continued)

35. NOTE: Install the engine front cover within 10

33. CAUTION: Hold each camshaft by the
minutes of applying the sealer.
hexagon with an open-ended wrench
to stop it from turning. Apply a 3 mm bead of sealant to the en-
gine front cover.
Tighten the camshaft sprockets retaining
bolts.

34. Using Loctite 7070, clean the engine front

cover mating faces.

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303-01A-120 Engine — 1.8L/2.0L 303-01A-120

ASSEMBLY (Continued)
36. Install the engine front cover. 38. NOTE: Only turn the engine in the normal
• Tighten the bolts in the sequence shown. direction of rotation.
• Bolts 1 through 8 to 10 Nm Using the crankshaft pulley retaining
• Bolt 9: 48 Nm bolt, turn the engine until piston No. 1 is
at TDC.
• Bolts 10 through 19 to 10 Nm
• Bolts 20 through 22 to 48 Nm

39. Remove the crankshaft pulley retaining

bolt.
• Discard the bolt.
40. CAUTION: Only tighten the crankshaft
pulley securing bolt finger tight.
Install the crankshaft pulley onto the
crankshaft and secure the crankshaft pul-
ley to the front cover using a M6 x 18 mm
bolt.

37. Remove the cylinder block lower blank-

ing plug from the cylinder block and in-
stall the special tool.

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303-01A-121 Engine — 1.8L/2.0L 303-01A-121

ASSEMBLY (Continued)

41. NOTE: Install a new crankshaft pulley

44. Remove the special tool.
retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and
tighten the crankshaft pulley retaining
bolt.
• Tighten the bolt in two stages.
• Stage 1: 100 Nm.
• Stage 2: 90 degrees.

45. NOTE: Only turn the engine in the normal

direction of rotation.
Turn the engine two revolutions.
46. Install the special tool.

42. Remove the crankshaft pulley securing

bolt.

47. NOTE: Only turn the engine in the normal

direction of rotation.
Turn the engine until piston No. 1 is at
TDC.

43. Remove the special tool.

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303-01A-122 Engine — 1.8L/2.0L 303-01A-122

ASSEMBLY (Continued)

48. CAUTION: Only tighten the crankshaft

51. Remove the crankshaft pulley securing
pulley securing bolt finger tight.
bolt.
NOTE: If it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.
Using a M6 x 18 mm bolt, check the posi-
tion of the crankshaft pulley.

52. Remove the special tool.

49. NOTE: If it is not possible to install the

special tool, correct the engine timing.
Using the special tool, check the position
of the camshafts.

53. Install the cylinder block lower blanking

plug.

50. Remove the special tool.

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303-01A-123 Engine — 1.8L/2.0L 303-01A-123

ASSEMBLY (Continued)

54. NOTE: When installing a new crankshaft 56. Install the water pump pulley.
pulley or engine front cover, the crankshaft
position (CKP) sensor must be aligned using
the tool supplied with the new component.
NOTE: Do not tighten the bolts at this stage.
Align the CKP sensor.
1. Loosen the CKP sensor retaining bolts.
2. Insert the tool supplied, so that its hooked
in the crankshaft pulley teeth.

57. Install the accessory drive belt idler pul-

ley.

55. Install the CKP sensor.

1. Tighten the CKP sensor retaining bolts.
2. Remove the tool.

58. Apply a small bead of sealant to the ar-

eas as shown.

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303-01A-124 Engine — 1.8L/2.0L 303-01A-124

ASSEMBLY (Continued)
59. NOTE: Install a new valve cover gasket if 62. NOTE: Install a new exhaust manifold gasket.
necessary.
Install the exhaust manifold.
Install the valve cover.
• Tighten the bolts in the sequence shown.

63. Install the power steering pump.

60. Using the special tool, install the spark

plugs.

64. Using the special tool, install the coolant

hoses.

61. Using the special tool, connect the spark

plug electrical connectors.

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303-01A-125 Engine — 1.8L/2.0L 303-01A-125

ASSEMBLY (Continued)

65. Connect the positive crankcase ventila- 68. Using the special tool and an engine
tion hose (PCV) to the intake manifold. hoist, support the engine.

66. Install the intake manifold. 69. Remove the special tools.

67. Install the oil level indicator tube.

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303-01A-126 Engine — 1.8L/2.0L 303-01A-126

INSTALLATION

Engine — Vehicles With: Automatic Transaxle

INSTALLATION

1. CAUTION: The torque converter hub

must engage fully in the oil pump
Special Tool(s) drive gear.

Expander, Teflon Seal Check the installation depth of the torque

converter.
211-188 (13-015)
1. Lay a steel straightedge across the
automatic transaxle flange.
2. Check the installation depth between the
steel straight edge and the drive plate..
Lifting Bracket, Engine 3. Apply a thin layer of high temperature
303-122 (21-068A) grease to the centering spigot on the
torque converter.

Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

General Equipment
Workshop Table
Engine Hoist

Name Specification
High Temperature ESD-M1C220-A
Grease
All vehicles
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 ignite.
Failure to follow these instructions may
result in personal injury.

2. NOTE: Do not support the oil pan. Using

suitable securing straps, secure the engine on
the workshop table.
Using wooden blocks, support the engine.
3. Install the transaxle.

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303-01A-127 Engine — 1.8L/2.0L 303-01A-127

INSTALLATION (Continued)

4. Install the transaxle upper retaining bolts. 7. NOTE: Install new torque converter retaining
nuts.
Install the torque converter retaining nuts
(four nuts).
• Rotate the engine to gain access to the
nuts.
• Install the cover.

5. Install the transaxle lower retaining bolts.

8. Install the starter motor.

6. Install the transaxle right-hand retaining

bolts.

9. Install the wiring harness retaining

bracket.
• Attach the wiring harness to the retaining
bracket.

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303-01A-128 Engine — 1.8L/2.0L 303-01A-128

INSTALLATION (Continued)
12. NOTE: Install a new engine rear mount
10. Install the transaxle left-hand retaining
retaining nut.
bolts.
NOTE: Do not tighten the engine rear mount
retaining nut at this stage.
Install the engine rear mount retaining
nut.

11. Position the workshop table under the

vehicle and carefully lower the vehicle
until the engine and transaxle assembly
is in the correct position to install the en-
gine mounts. 13. NOTE: Install new engine front mount
retaining nuts.
NOTE: Do not tighten the retaining nuts and
retaining bolts at this stage.
Install the engine front mount.

14. Remove the retaining straps from the

transaxle.
15. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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303-01A-129 Engine — 1.8L/2.0L 303-01A-129

INSTALLATION (Continued)

16. Connect the wiring harness electrical 19. CAUTION: Support the halfshaft. The
connectors. inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
CAUTION: Make sure the snap ring is
correctly seated.
NOTE: Install a new snap ring.
Attach the left-hand halfshaft to the
transaxle.

17. Attach the air conditioning (A/C) com-

pressor to the mounting bracket.

20. CAUTION: Support the halfshaft. The

inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.

18. Connect the crankshaft position (CKP) CAUTION: Do not damage the halfshaft
sensor electrical connector. oil seal.
NOTE: Install a new center bearing cap and new
retaining nuts.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.

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303-01A-130 Engine — 1.8L/2.0L 303-01A-130

INSTALLATION (Continued)

21. Connect the wiring harness electrical 24. CAUTION: Use an open ended
connectors. spanner on the fluid line adaptor to
prevent it from turning.
Attach the fluid cooler pipe to the
transaxle.
• Attach the fluid pipe bracket to the trans-
axle.

22. CAUTION: Use an open ended

spanner on the fluid line adapter to
prevent it from turning.
Attach the fluid cooler return pipe to the
transaxle.
25. Connect the output shaft speed (OSS)
sensor electrical connector.

23. Connect the turbine shaft speed (TSS)

sensor electrical connector.
• Install the wiring retaining clip. 26. Install the subframe. For additional
information, refer to Section 502-00.
27. Lower the vehicle.

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303-01A-131 Engine — 1.8L/2.0L 303-01A-131

INSTALLATION (Continued)

28. Tighten the engine rear mount retaining 31. Connect the power steering line to the
nut. power steering pump.

29. Tighten the engine front mount retaining 32. Install the power steering pump pulley.
nuts and retaining bolts. For additional information, refer to
Section 211-02.
33. Install the power steering line support
retaining nut.

30. Using the special tool, install a new O-

ring seal onto the power steering line to
power steering pump union.
1. Push the O-ring seal onto the special tool. 34. Install new O-ring seals.
2. Locate the special tool onto the union and
install the O-ring seal.

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303-01A-132 Engine — 1.8L/2.0L 303-01A-132

INSTALLATION (Continued)
35. Install the power steering fluid reservoir. 38. Attach the battery ground lead to the
1. Install the front retaining bolts. transaxle.
2. Install the retaining stud.

39. Connect the automatic transmission

control electrical connector.
36. Connect the power steering hose to the
power steering fluid reservoir. • Install the cable ties.
• Attach the wiring harness retaining clip to
the retaining bracket.

37. Install the engine wiring harness bracket.

40. Connect the transmission range (TR)

sensor electrical connector.

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303-01A-133 Engine — 1.8L/2.0L 303-01A-133

INSTALLATION (Continued)

41. Connect the heated oxygen (HO2S) sen- 44. Connect the fuel supply line. For addi-
sor electrical connector. tional information, refer to Section 310-
00.

42. Attach the selector lever cable to the

transaxle. 45. Connect the vacuum hoses to the intake
1. Install the selector lever cable bracket. manifold.
2. Attach the selector lever cable to the trans-
axle.

46. Attach the coolant expansion tank to the

wheel housing.
43. Install the cooling fan motor and shroud.
1. Connect the electrical connector.
2. Install the nuts on both sides (left-hand
side shown).

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303-01A-134 Engine — 1.8L/2.0L 303-01A-134

INSTALLATION (Continued)
47. Using the special tool, install the coolant 50. Attach the power steering line retaining
hose. bracket to the valve cover.

48. Using the special tool, connect the cool- 51. Connect the engine wiring harness
ant hoses to the coolant connecting pipe. electrical connectors.
• Install a new clip.

49. Connect the generator electrical connec-

tors. 52. Connect the wiring harness electrical
connectors.

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303-01A-135 Engine — 1.8L/2.0L 303-01A-135

INSTALLATION (Continued)

Vehicles with speed control 55. Install the air cleaner housing.
53. Attach the speed control cable to the 1. Connect the positive crankcase ventilation
retaining bracket. (PCV) hose.
1. Attach the inner cable to the throttle body. 2. Attach the hose clamp to the intake air
2. Attach the speed control cable retaining cleaner outlet pipe.
bracket to the throttle body.

56. Fill the cooling system. For additional

All vehicles information, refer to Section 303-03.
54. Attach the accelerator cable to the 57. Fill and bleed the power steering system.
retaining bracket. For additional information, refer to
1. Turn the cable into the bracket. Section 211-00.
2. Attach the inner cable to the throttle body. 58. Connect the battery ground cable. For
additional information, refer to Section
414-01.
59. Tighten the strut and spring assembly
top mount retaining nuts on both sides.

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303-01A-136 Engine — 1.8L/2.0L 303-01A-136

INSTALLATION (Continued)
60. Install the strut and spring assembly top
mount brace cover on both sides.

61. Install the engine upper cover.

62. Attach the PCV hose and the vacuum

hose to the engine upper cover.

63. Initialize the door window motors. For

additional information, refer to Section
501-11.

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303-01B-1 Engine 303-01B-1

SECTION 303-01B Engine

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-01-2

DIAGNOSIS AND TESTING

Engine ............................................................................................................................... 303-01-6

IN-VEHICLE REPAIR

Upper Intake Manifold .................................................................................. (21 183 0) 303-01-7

Valve Cover LH ............................................................................................ (21 141 0) 303-01-11
Valve Cover RH............................................................................................ (21 140 0) 303-01-14
Crankshaft Pulley ......................................................................................... (21 572 0) 303-01-17
Crankshaft Front Seal................................................................................... (21 467 0) 303-01-19
Valve Springs .................................................................................................................... 303-01-20
Valve Seals .................................................................................................. (21 238 0) 303-01-22
Camshaft Seal.............................................................................................. (21 288 0) 303-01-23
Exhaust Manifold LH .................................................................................... (21 187 0) 303-01-25
Exhaust Manifold RH.................................................................................... (21 186 0) 303-01-27
Oil Pan ......................................................................................................... (21 154 0) 303-01-30
Crankshaft Rear Seal ................................................................................... (21 468 4) 303-01-33

REMOVAL AND INSTALLATION

Engine — Vehicles With: Automatic Transaxle .................................................................. 303-01-36

DISASSEMBLY

Engine .......................................................................................................... (21 134 8) 303-01-44

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head............................................................................................... (21 165 6) 303-01-63

ASSEMBLY

Engine .......................................................................................................... (21 134 8) 303-01-66

INSTALLATION

Engine — Vehicles With: Automatic Transaxle .................................................................. 303-01-95

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303-01B-2 Engine — 2.5L 303-01B-2

SPECIFICATIONS

Engine Data
Description
Firing order 1–4–2–5–3–6
Engine management EEC V
Emission standard Stage IV
Engine code LCBD
Bore (mm) 81.66
Stroke (mm) 79.5
Number of main bearings 5
Displacement (cm 3 ) 2499
Compression ratio 9,7:1
Power output kW /PS 125/170
Power output at (rev/min) 6250
Torque (Nm) 220
Torque at (rev/min) 4250
Idle speed (rpm) 725
Number of crankshaft main bearings 4
Number of camshaft bearings 4
Camshaft operation Chain
Intake valve clearance Hydraulic adjustment
Exhaust valve clearance Hydraulic adjustment
Spark plug AWSF32 F

Engine Oil
Description Viscosity Specification
Recommended engine oil
Formula E SAE 5W–30 WSS–M2C913–A
WSS–M2C912 A1
Alternative engine oils
Formula S SAE 5W–40 ACEA A3/B3
XR+ High Performance SAE 10W–40 ACEA A3/B3

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Coolant WSS–M97B44–D
Power steering hydraulic fluid ESP–M2C166–H
Sealer – lower crankcase to cylinder block, mating faces – oil pan to lower WSK–M4G320–A
crankcase, mating faces – cylinder head covers to cylinder heads, keyway –
crankshaft vibration damper.
Sealer – coolant plug to cylinder block ESK–M4G260–A
Sealer – oil pressure switch, blanking plugs – oil and coolant passages SM–4G–4644–AA/AB
Lubricant – O-rings – coolant connecting pipe WSS–M97B44–D
Lubricant – spark plugs (Never Seeze) ESE–M1244–A

Capacities
Litres
Engine oil, initial fill including oil filter 6.0
Engine oil, including oil filter change 5.5
Engine oil, including oil filter change 5.0
Engine coolant 9.5

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303-01B-3 Engine — 2.5L 303-01B-3

SPECIFICATIONS (Continued)

Cylinder Block
Description mm
Cylinder block bore diameter, Class 1 81.640 – 81.650
Cylinder block bore diameter, Class 2 81.651 – 81.660
Cylinder block bore diameter, Class 3 81.661 – 81.670
Main bearing bore diameter 68.998 – 69.002

Pistons
Description mm
Piston diameter, Class A 81.630 – 81.650
Piston diameter, Class B 81.638 – 81.662
Piston diameter, Class C 81.650 – 81.670
Piston ring gaps (installed)
– upper compression ring 0.100 – 0.250
– lower compression ring 0.27 – 0.42
– oil control ring 0.15 – 0.65
Ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston This
also applies to the oil control ring elements. Align the ring gaps at 120 degrees to each other.

Crankshaft
Description mm
Crankshaft end play 0.135 – 0.255
Main bearing journal diameter, rear 62.968 – 62.992

Connecting Rods
Description mm
Bore diameter, small end 21.071 – 21.032
Connecting rod length 138.06 – 138.4
Connecting rod clearance (radial) 0.028 – 0.066
Connecting rod bearing clearance (axial) 0.100 – 0.300

Piston Pin
Description mm
Piston pin length 55.05 – 55.47
Piston pin diameter 21.011 – 21.013
Piston pin clearance in piston -0.005 – +0.001
Piston pin to connecting rod clearance (radial) 0.028 – 0.066
Piston pin to connecting rod clearance (axial) 0.004 – 0.020

Camshafts
Description mm
Bearing journal diameter 26.926 – 26.936
Bearing inside diameter 27.012 – 26.897
Camshaft end play 0.025 – 0.165

Valves
Description mm
Valve stem clearance (exhaust) 0.045 – 0.094
Valve stem clearance (intake) 0.020 – 0.069

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303-01B-4 Engine — 2.5L 303-01B-4

SPECIFICATIONS (Continued)

Description mm
Valve head diameter (exhaust) 26
Valve head diameter (intake) 32

Cylinder Head
Description mm
Maximum distortion (mating surface)
Peak – to – valley height of mating surface (reference length mm vertical to
groove direction)

Lubrication System
Description bar
Max. oil pressure at 1500 rpm 3.1

Torque Specifications
Description Nm lb-ft lb-in
Transaxle retaining bolts 40 30 –
Engine mounting bracket to cylinder block 47 35 –
Front engine mounting 83 61 –
Rear engine mounting (MTX–75) 80 59 –
Center bolt to rear engine roll restrictor 80 59 –
Front exhaust pipe 40 30 –
Rear catalytic converter 40 30 –
Left and right-hand top mount nut 59 44 –
Starter motor bracket 48 35 –
Ground cable to automatic transmission housing 40 30 –
Mounting plate to cylinder block 47 35 –
Blanking plug – oil pump 10 – 89
Oil pump cover to oil pump 10 – 89
Oil pump to cylinder block 10 – 89
Oil baffle to lower crankcase 10 – 89
Oil intake pipe to lower crankcase, M6 10 – 89
Oil intake pipe to lower crankcase, M8 25 18 –
Oil line to radiator 23 17 –
Oil separator to cylinder block 10 – 89
Oil baffle to oil pan 10 – 89
Oil drain plug to oil pan 26 19 –
Oil pan to lower crankcase 25 18 –
Oil pressure switch to cylinder block 14 10 –
Cylinder head bolts, stage (refer to procedure in
this section)
Lower crankcase to cylinder block (refer to proce-
dure in this section)
Connecting rod bearing caps, stage (refer to pro-
cedure in this section)
Camshaft bearing caps to cylinder head 10 – 89
Camshaft oil seal housing to cylinder head 10 – 89
Fixed timing chain guide to cylinder block 25 18 –
Timing chain tensioner to cylinder block 25 18 –
Timing case cover to cylinder block 25 18 –
Wiring harness bracket to timing case cover 10 – 89

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303-01B-5 Engine — 2.5L 303-01B-5

SPECIFICATIONS (Continued)

Description Nm lb-ft lb-in

Camshaft position sensor to timing case cover 10 – 89
Crankshaft position sensor to timing case cover 10 – 89
Pulley/vibration damper to crankshaft (refer to pro-
cedure in this section)
Power steering pump to carrier of engine mounting 25 18 –
bracket
Power steering pump bracket to timing case cover 10 – 89
Pulley to power steering pump 25 18 –
Stud of the power steering pump 10 – 89
Spark plugs 14 10 –
Cylinder head cover to cylinder head 10 – 89
Wiring harness retaining plate to cylinder head 10 – 89
cover
Exhaust manifold to cylinder head (refer to proce-
dure in this section)
Knock sensor to cylinder head 34 25 –
Generator bracket to cylinder block 25 18 –
Generator mounting bolts 47 35 –
Engine drive plate to crankshaft 80 59 –
Flywheel to crankshaft 80 59 –
Camshaft oil seal carrier 10 89
Water pump to cylinder head (refer to procedure in
this section)
Coolant connecting pipe to cylinder head 10 – 89
Positive crankcase ventilation bracket to coolant 6 – 89
connecting pipe
Coolant distribution pipe to cylinder head 6 – 89
Oil dipstick tube bracket to coolant distribution pipe 10 – 89
Wiring harness to cylinder head cover 5 – 44
Generator power connection 10 – 89
Lower intake manifold to cylinder heads (refer to
procedure in this section)
Upper intake manifold to valve cover (refer to pro-
cedure in this section)
Intake manifold runner control actuator 10 – 89
EI coil to cylinder head cover 6 – 53
Ground cable to EI coil 6 – 53
Front driveshaft intermediate shaft bracket to cyl- 47 35 –
inder block
Exhaust gas recirculation pipe to EGR valve 40 30 –
Unspecified bolt usage: M5 x 0,8 6 – 53
Unspecified bolt usage: M6 x 1 10 – 89
Unspecified bolt usage: M8 x 1,25 25 18 –
Unspecified bolt usage: M10 x 1,5 47 35 –
Unspecified bolt usage: M12 x 1,75 82 60 –
Unspecified bolt usage: M14 x 2 132 97 –

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303-01B-6 Engine — 2.5L 303-01B-6

DIAGNOSIS AND TESTING

Engine
DIAGNOSIS AND TESTING

REFER to Section 303-00.

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303-01B-7 Engine — 2.5L 303-01B-7

IN-VEHICLE REPAIR

Upper Intake Manifold (21 183 0)

IN-VEHICLE REPAIR

Removal 4. Detach the accelerator cable.

1. Disconnect the battery ground cable. For • Detach the clips and the accelerator cable
additional information, refer to Section from the bracket.
414-01.
2. Disconnect the air intake hose from the
upper intake manifold.
• Detach the hose clamp.

5. Disconnect the idle air control (IAC) valve

electrical connector.

3. Disconnect the brake booster vacuum pipe

from the upper intake manifold.

6. Disconnect the throttle position (TP) sen-

sor electrical connector.

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303-01B-8 Engine — 2.5L 303-01B-8

IN-VEHICLE REPAIR (Continued)

7. Remove the exhaust gas recirculation 10. Disconnect the EVR vacuum hose.
(EGR) valve from the upper intake
manifold.
1. Disconnect the EGR valve vacuum hose.
2. Remove the bolts.
• Discard the gasket.

11. NOTE: Remove the upper intake manifold

retaining bolts in the sequence shown.
Remove the upper intake manifold.
• Discard the gaskets.

8. Disconnect the positive crankcase ventila-

tion (PCV) hose.

9. Disconnect the electronic vacuum regula-

tor (EVR) solenoid electrical connector.

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303-01B-9 Engine — 2.5L 303-01B-9

IN-VEHICLE REPAIR (Continued)

Installation 4. Connect the PCV hose.

1. NOTE: Make sure insulating bushes are on the

upper intake manifold retaining bolts.
Install the upper intake manifold with new
gaskets.
• Tighten the bolts in the sequence shown.

5. NOTE: Install a new gasket gasket.

Install the EGR valve to the upper intake
manifold.
1. Install the retaining bolts.
2. Connect the EGR valve vacuum hose.
2. Connect the EVR vacuum hose.

6. Connect the TP sensor electrical connec-

tor.
3. Connect the EVR solenoid electrical con-
nector.

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303-01B-10 Engine — 2.5L 303-01B-10

IN-VEHICLE REPAIR (Continued)

7. Connect the IAC valve electrical connec- 10. Connect the air intake hose to the upper
tor. intake manifold.
• Attach the hose clamp.

8. Attach the accelerator cable.

• Attach the clips and accelerator cable to 11. Connect the battery ground cable. For
the bracket. additional information, refer to Section
414-01.
12. Initialize the door window motors. For
additional information, refer to Section
501-11.

9. Connect the brake booster vacuum pipe.

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303-01B-11 Engine — 2.5L 303-01B-11

IN-VEHICLE REPAIR

Valve Cover LH (21 141 0)

4. Detach the cable bridge and position the
IMRC actuator to one side.
Name Specification
Sealer WSE-M4G323-A6

Removal
All vehicles
1. Remove the engine upper cover.

All vehicles
5. Disconnect the left-hand spark plug
electrical connectors.
• Detach the bracket.

2. Remove the upper intake manifold. For

additional information, refer to Upper
Intake Manifold in this section.
Vehicles with automatic transaxle
3. Remove the intake manifold runner control
(IMRC) actuator bolts.

6. Detach the coolant hose from the bracket

(if equipped).
• Detach the bracket from the retaining stud.

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303-01B-12 Engine — 2.5L 303-01B-12

IN-VEHICLE REPAIR (Continued)

7. Detach the wiring harness from the left- 2. Apply sealer to the mating faces of the
hand valve cover. cylinder head.

8. NOTE: Remove the left-hand valve cover 3. NOTE: Install a new gasket.
retaining bolts in the sequence shown. NOTE: Tighten the valve cover retaining bolts in
Remove the left-hand valve cover. the sequence shown.
• Discard the gasket. Install the left-hand valve cover.

4. Attach the wiring harness to the left-hand

Installation valve cover.

All vehicles
1. Clean the mating faces of the cylinder
head and the left-hand valve cover with a
clean lint free cloth.

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303-01B-13 Engine — 2.5L 303-01B-13

IN-VEHICLE REPAIR (Continued)

5. Attach the coolant hose to the bracket (if 8. Install the IMRC actuator bolts.
equipped).
• Attach the bracket to the retaining stud.

9. Install the upper intake manifold. For

additional information, refer to Upper
6. Connect the left-hand spark plug electrical Intake Manifold in this section.
connectors. All vehicles
• Attach the bracket. 10. Install the engine upper cover.

Vehicles with automatic transaxle

7. Position the IMRC actuator and install the
bridge.

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303-01B-14 Engine — 2.5L 303-01B-14

IN-VEHICLE REPAIR

Valve Cover RH (21 140 0)

4. Detach the front wiring harness bracket
from the right-hand valve cover (if
equipped).
Name Specification
Sealer WSE-M4G323-A6

Removal
1. Remove the upper intake manifold. For
additional information, refer to Upper
Intake Manifold in this section.
2. Disconnect the right-hand spark plug
electrical connectors.
• Detach the bracket.

5. Detach the rear wiring harness bracket

from the right-hand valve cover (if
equipped).

3. Remove the electronic ignition (EI) coil.

• Disconnect the electrical connectors.

6. Detach the wiring rail from the right-hand

valve cover.

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303-01B-15 Engine — 2.5L 303-01B-15

IN-VEHICLE REPAIR (Continued)

7. NOTE: Remove the right-hand valve cover 2. NOTE: Install a new gasket.
retaining bolts in the sequence shown. NOTE: Tighten the valve cover retaining bolts in
Remove the right-hand valve cover. the sequence shown.
• Discard the gasket. Install the right-hand valve cover.

3. Attach the wiring rail to the right-hand

Installation valve cover.

1. Clean the mating faces of the cylinder

head and the right-hand valve cover with a
clean lint free cloth.
• Apply sealer to the mating faces of the cyl-
inder head.

4. Attach the rear wiring harness bracket to

the right-hand valve cover (if equipped).

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303-01B-16 Engine — 2.5L 303-01B-16

IN-VEHICLE REPAIR (Continued)

5. Attach the front wiring harness bracket to
the right-hand valve cover (if equipped).

6. Install the EI coil.

• Connect the electrical connectors.

7. Connect the right-hand spark plug

electrical connectors.
• Attach the bracket.

8. Install the upper intake manifold. For

additional information, refer to Upper
Intake Manifold in this section.

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303-01B-17 Engine — 2.5L 303-01B-17

IN-VEHICLE REPAIR

Crankshaft Pulley (21 572 0)

3. Using the special tool, remove the
crankshaft pulley retaining bolt.
• Discard the bolt.
Special Tool(s)
Flange Holding Wrench,
Universal
205-072 (15-030A)

Remover/ Installer,
Crankshaft Vibration Damper
303-130 (21-076)

Angle Gauge, Bolt Tightening

303-174 (21-540) 4. Using the special tool, remove the crank-
shaft pulley.

Remover, Crankshaft
Vibration Damper
303-338 (21-153B)

Name Specification
Sealer (Loctite 5900) WSE-M4G323-A6

Removal
1. Remove the accessory drive belt. For
additional information, refer to Section
303-05.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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303-01B-18 Engine — 2.5L 303-01B-18

IN-VEHICLE REPAIR (Continued)

Installation
1. NOTE: Use the crankshaft pulley retaining bolt
washer for installation.
Using the special tool, install the crank-
shaft pulley.

2. NOTE: Install a new retaining bolt.

NOTE: Coat the Woodruff key groove and the
crankshaft pulley retaining bolt with sealer.
Using the special tool, tighten the
crankshaft pulley retaining bolt in four
stages.
1. Stage 1: 120 Nm
2. Stage 2: Loosen the retaining bolt by 360
degrees.
3. Stage 3: 50 Nm
4. Stage 4: 90 degrees

3. Install the accessory drive belt. For

additional information, refer to Section
303-05.
4. Lower the vehicle.

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303-01B-19 Engine — 2.5L 303-01B-19

IN-VEHICLE REPAIR

Crankshaft Front Seal (21 467 0)

2. Using the special tool, remove the crank-
shaft front oil seal.
Special Tool(s)
Installer/Aligner, Timing
Cover Oil Seal
303-055 (21-017 A)

Remover, Oil Seal

303-112 (21-051)

Remover/Installer,
Crankshaft Vibration Damper
303-130 (21-076)
Installation
1. NOTE: Use the crankshaft pulley bolt washer
for installation.
NOTE: Lubricate the outer ring of the oil seal with
Name Specification engine oil.
Vehicles built up to Using the special tool, install the crank-
10/2000: shaft front oil seal.
Engine oil WSS-M2C912-A1/
WSS-M2C913-A
Vehicles built 10/2000
onwards:
Engine oil WSS-M2C913-A

Removal
1. Remove the crankshaft pulley. For
additional information, refer to Crankshaft
Pulley in this section.

2. Install the crankshaft pulley. For

additional information, refer to Crankshaft
Pulley in this section.

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303-01B-20 Engine — 2.5L 303-01B-20

IN-VEHICLE REPAIR

Valve Springs
3. CAUTION: The piston of the cylinder to
be worked on must be at bottom dead
Special Tool(s) center (BDC) and both valves be
closed. Sudden loss of compressed
Installer, Valve Stem Collets air pressure could cause the valve to
303-362 (21-156) drop into the cylinder.
Remove the spark plugs.

Adapter, Air Supply (Cylinder

Head)
303-363 (21-157)

Compressor, Valve Spring

303-461 (21-194)

Adapter for 303-461 4. Using the special tool, apply approxi-

303-461-01 (21-194-01) mately 7 - 10 bar of compressed air to the
appropriate cylinder.

Socket, Spark Plug

303-499 (21-202)

Removal
1. Remove the left-hand valve cover. For
additional information, refer to LH Valve
Cover in this section.
2. Remove the right-hand valve cover. For
additional information, refer to RH Valve
Cover in this section.

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303-01B-21 Engine — 2.5L 303-01B-21

IN-VEHICLE REPAIR (Continued)

5. Using the special tool, remove the cam fol- 2. Using the special tool, install the cam fol-
lowers. lower.

6. Using the special tools, remove the valve 3. Remove the special tool.
springs.

4. Install the spark plugs.

Installation
1. Using the special tools, install the valve
springs.

5. Install the right-hand valve cover. For

additional information, refer to RH Valve
Cover in this section.
6. Install the left-hand valve cover. For
additional information, refer to LH Valve
Cover in this section.

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303-01B-22 Engine — 2.5L 303-01B-22

IN-VEHICLE REPAIR

Valve Seals (21 238 0)

Installation
Special Tool(s)
1. Cover the collet groove with the valve
Installer, Intake Valve Stem stem protective sleeve (valve shown re-
Oil Seal moved for clarity).
303-247 (21-130A)

Pliers, Valve Stem Oil Seal

303-508 (21-211)

General Equipment
Protective sleeve - valve stem

2. NOTE: Install new oil seals.

Removal
Using the special tool, install the valve
1. Remove the valve springs. For additional stem oil seals.
information, refer to Valve Springs in this
section.
2. Using the special tool, remove the valve
stem oil seals.

3. Install the valve springs. For additional

information, refer to Valve Springs in this
section.

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303-01B-23 Engine — 2.5L 303-01B-23

IN-VEHICLE REPAIR

Camshaft Seal (21 288 0)

2. Remove the water pump drive belt.
• Rotate the belt tensioner clockwise to re-
lease the tension on the drive belt.
Special Tool(s)
Remover, Crankshaft Oil
Seal
303-293 (21-143)

Adapter for 303-338

303-338-02 (21-153 A-02)

Remover, Crankshaft
Vibration Damper
3. Using the special tools, remove the cam-
303-338 (21-153B) shaft pulley.

Installer, Camshaft Pulley

303-458 (21-192)

Adapter for 303-458

303-458-01 (21-192-01)

4. Using the special tool, remove the

Name Specification camshaft oil seal.
Engine oil WSS-M2C913-A • Discard the seal.

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.

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303-01B-24 Engine — 2.5L 303-01B-24

IN-VEHICLE REPAIR (Continued)

Installation 4. Connect the battery ground cable. For
additional information, refer to Section
1. NOTE: Install a new oil seal. 414-01.
Using the special tools, install the 5. Initialize the door window motors. For
camshaft oil seal. additional information, refer to Section
• Lubricate the oil seal with engine oil. 501-11.

2. Using the special tool, install the camshaft

pulley.

3. Install the water pump drive belt.

• Rotate the belt tensioner clockwise to re-
lease the tension on the belt.

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303-01B-25 Engine — 2.5L 303-01B-25

IN-VEHICLE REPAIR

Exhaust Manifold LH (21 187 0)

Removal
4. CAUTION: Remove the left-hand
1. Remove the engine upper cover. exhaust manifold retaining nuts in the
sequence shown.
Remove the left-hand exhaust manifold
(engine shown removed for clarity).
• Discard the gaskets and retaining nuts.

2. Disconnect the left-hand heated oxygen

sensor (HO2S) electrical connector.

Installation
1. NOTE: Install new gaskets and retaining nuts.
Install the left-hand exhaust manifold.
• Tighten the nuts in the sequence shown.

3. Remove the dual converter y-pipe. For

additional information, refer to Section
309-00.

2. Install the dual converter y-pipe. For

additional information, refer to Section
309-00.

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303-01B-26 Engine — 2.5L 303-01B-26

IN-VEHICLE REPAIR (Continued)

3. Connect the HO2S sensor electrical con-
nector.

4. Install the engine upper cover.

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303-01B-27 Engine — 2.5L 303-01B-27

IN-VEHICLE REPAIR

Exhaust Manifold RH (21 186 0)

Removal 5. Remove the engine right-hand roll restric-

tor center bolt.
1. Remove the generator. For additional
information, refer to Section 414-02.
2. Loosen the exhaust gas recirculation
(EGR) valve retaining bolts (if equipped).

6. Using a suitable wooden block, support

the right-hand side of the engine.

3. Remove the dual converter y-pipe. For

additional information, refer to Section
309-00.
4. Disconnect the right-hand heated oxygen
sensor (HO2S) electrical connector (if
equipped).

7. Detach the EGR pipe from the right-hand

exhaust manifold (if equipped).

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303-01B-28 Engine — 2.5L 303-01B-28

IN-VEHICLE REPAIR (Continued)

8. CAUTION: Remove the right-hand 2. Attach the EGR pipe to the right-hand ex-
exhaust manifold retaining nuts in the haust manifold (if equipped).
sequence shown.
Remove the right-hand exhaust manifold
(engine shown removed for clarity).
• Discard the gasket and the retaining nuts.

3. Remove the wooden block.

Installation
1. NOTE: Install new gaskets and retaining nuts.
NOTE: Tighten the nuts in the sequence shown.
Install the right-hand exhaust manifold.

4. Install the engine right-hand roll restrictor

center bolt.

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303-01B-29 Engine — 2.5L 303-01B-29

IN-VEHICLE REPAIR (Continued)

5. Connect the H02S electrical connector (if

equipped).

6. Install the dual converter y-pipe. For

additional information, refer to Section
309-00.
7. Tighten the EGR valve retaining bolts (if
equipped).

8. Install the generator. For additional

information, refer to Section 414-02.

G37478 en 08/2002 2003.0 Mondeo

303-01B-30 Engine — 2.5L 303-01B-30

IN-VEHICLE REPAIR

Oil Pan (21 154 0)

4. Remove the oil pan flange retaining bolts.

Name Specification
Sealer WSE-M4G323-A6
Engine oil WSS-M2C913-A

Removal
1. Remove the dual converter y-pipe. For
additional information, refer to Section
309-00.
2. NOTE: Inspect the oil pan drain plug seal for
damage. Install a new drain plug and seal if
required. 5. NOTE: Remove the oil pan retaining bolts in
the sequence shown.
Drain the engine oil.
• Install the drain plug. Remove the oil pan.
• Discard the gasket.

3. Remove the exhaust front pipe bracket

from the cylinder block.

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303-01B-31 Engine — 2.5L 303-01B-31

IN-VEHICLE REPAIR (Continued)

Installation 3. Install the oil pan flange retaining bolts.

1. CAUTION: Install the oil pan within five

minutes of applying the sealer.
Apply sealer approximately 10 mm in di-
ameter where indicated.

4. NOTE: Location of the stud bolts.

Install the oil pan retaining bolts and stud
bolts.
• Tighten the retaining bolts and stud bolts in
the sequence shown.
2. NOTE: Use a new gasket.
NOTE: Do not fully tighten the oil pan retaining
bolts at this stage.
Install the oil pan.

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303-01B-32 Engine — 2.5L 303-01B-32

IN-VEHICLE REPAIR (Continued)

5. Install the exhaust front pipe bracket.

6. Install the dual converter y-pipe. For

additional information, refer to Section
309-00.
7. Fill the engine with engine oil.

G37479 en 08/2002 2003.0 Mondeo

303-01B-33 Engine — 2.5L 303-01B-33

IN-VEHICLE REPAIR

Crankshaft Rear Seal (21 468 4)

Vehicles with automatic transaxle
3. Remove the automatic transaxle. For
additional information, refer to Section
Special Tool(s)
307-01A / 307-01B.
Locking Tool, Flywheel 4. Remove the flexplate.
303-254 (21-135) 1. Remove the flexplate retaining bolts.
2. Remove the adapter plate.

Remover, Crankshaft Oil

Seal
303-293 (21-143)

Installer, Crankshaft Rear Oil

Seal
303-460 (21-193A)

All vehicles
Name Specification 5. Using the special tool, remove the
Sealer WSE-M4G323-A6 crankshaft rear oil seal.
• Discard the seal.
Engine oil WSS-M2C913-A

Removal
Vehicles with manual transaxle
1. Remove the clutch disc and pressure
plate.
2. Remove the flywheel
1. Remove the flywheel retaining bolts.
2. Remove the adapter plate.

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303-01B-34 Engine — 2.5L 303-01B-34

IN-VEHICLE REPAIR (Continued)

Installation Vehicles with manual transaxle
3. NOTE: Do not fully tighten the flywheel
All vehicles retaining bolts at this stage.
1. NOTE: Lubricate the sealing lip of the oil seal
Install the adapter plate and the flywheel.
with clean engine oil.
Using the special tool, install the crank-
shaft rear oil seal.

All vehicles
4. Using the special tool, lock the flywheel or
flexplate in position.
Vehicles with automatic transaxle
2. NOTE: Do not fully tighten the flexplate
retaining bolts at this stage.
Install the adapter plate and the flexplate.

5. Tighten the flywheel or flexplate retaining

bolts in the sequence shown.

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303-01B-35 Engine — 2.5L 303-01B-35

IN-VEHICLE REPAIR (Continued)

6. Remove the special tool.

Vehicles with manual transaxle

7. Install the clutch disc and pressure plate.
Vehicles with automatic transaxle
8. Install the automatic transaxle. For
additional information, refer to Section
307-01A / 307-01B.

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303-01B-36 Engine — 2.5L 303-01B-36

REMOVAL

Engine — Vehicles With: Automatic Transaxle

REMOVAL

3. Loosen the strut and spring assembly top

Special Tool(s) mount retaining nuts by four turns on both
sides.
Remover/Installer Cooling
Hose Clamp
303-397 (24-003)

Remover, Halfshaft
308-256 (16-089)

General Equipment
Workshop table 4. Remove the air cleaner.
Workshop hoist 1. Disconnect the positive crankcase
ventilation (PCV) hoses.
Securing straps
2. Disconnect the mass air flow (MAF) sensor
electrical connector.
Removal 3. Detach the air cleaner outlet hose.

1. 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
ignite. Failure to follow these
instructions may result in personal
injury.
Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the strut and spring assembly top
mount brace cover on both sides (left-
hand side shown). 5. Remove the engine upper cover.

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303-01B-37 Engine — 2.5L 303-01B-37

REMOVAL (Continued)

12. Detach the accelerator cable.

6. Detach the brake booster vacuum pipe
from the intake manifold. • Detach the clips and the accelerator cable
from the bracket.

7. Disconnect the fuel supply line. For addi-

tional information, refer to Section 310-00. 13. Using the special tool, disconnect the
coolant hoses from the coolant connect-
ing pipe.

8. Drain the cooling system. For additional

information, refer to Section 303-03.
14. Detach evaporative emission (EVAP) so-
9. Remove the accessory drive belt. For
lenoid valve from the intake manifold.
additional information, refer to Section
303-05.
10. Remove the subframe. For additional
information, refer to Section 502-00.
11. Lower the vehicle.

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303-01B-38 Engine — 2.5L 303-01B-38

REMOVAL (Continued)
15. Disconnect the electronic ignition (EI) 18. Detach the engine wiring harness from
coil electrical connectors. the right-hand valve cover.

16. Remove the EI coil. 19. Disconnect the engine wiring harness
electrical connectors.

17. Disconnect the heated oxygen sensor

(HO2S) electrical connector. 20. Disconnect the ground cable from the
transaxle.

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303-01B-39 Engine — 2.5L 303-01B-39

REMOVAL (Continued)

21. Disconnect the starter motor electrical 24. Using the special tool, disconnect the
connectors. power steering pump hose from the
power steering pump.
• Allow the fluid to drain into a suitable con-
tainer.

22. Detach the power steering pump line

support bracket from the engine front
mount.
25. Detach the power steering fluid reservoir
from the radiator grille opening panel and
position it to one side.

23. Disconnect the power steering line.

• Remove the clip.
• Allow the fluid to drain into a suitable con-
tainer. 26. Disconnect the vent hose from the trans-
axle.

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303-01B-40 Engine — 2.5L 303-01B-40

REMOVAL (Continued)

27. Raise and support the vehicle. For 29. CAUTION: Support the halfshaft. The
additional information, refer to Section inner joint must not be bent more than
100-02. 18 degrees. The outer joint must not
be bent more than 45 degrees.
28. CAUTION: Support the halfshaft. The
inner joint must not be bent more than NOTE: Do not damage the halfshaft oil seal.
18 degrees. The outer joint must not NOTE: Plug the transaxle to prevent oil loss or
be bent more than 45 degrees. dirt ingress.
NOTE: Do not damage the halfshaft oil seal. Detach the right-hand halfshaft and the
NOTE: Plug the transaxle to prevent oil loss or intermediate shaft from the transaxle and
dirt ingress. secure it to one side.
Using the special tool, detach the left- • Discard the center bearing cap and
hand halfshaft from the transaxle and locknuts.
secure it to one side. 1. Discard the O-ring seal
• Discard the snap ring.
• Discard the O-ring seal.

30. Using the special tool, disconnect the

lower coolant hose from the radiator.

G88905 en 08/2002 2003.0 Mondeo

303-01B-41 Engine — 2.5L 303-01B-41

REMOVAL (Continued)

31. Disconnect the air conditioning (A/C) 33. NOTE: Plug the fluid cooler pipes to prevent
electrical connector. oil loss or dirt ingress.
Disconnect the fluid cooler pipes from
the transaxle.
• Allow the fluid to drain into a suitable con-
tainer.

32. CAUTION: Support the A/C

compressor before removing the
retaining bolts and secure it to
prevent load being placed on the
refrigerant lines. 34. Disconnect the transaxle electrical con-
Detach the A/C compressor from the nectors.
mounting bracket and secure it to one
side.

35. Remove the selector cable cover.

G88905 en 08/2002 2003.0 Mondeo

303-01B-42 Engine — 2.5L 303-01B-42

REMOVAL (Continued)

36. NOTE: Make sure the transaxle selector lever 39. CAUTION: Do not support directly on
is in "P" (PARK) position. the oil pan.
Detach the selector lever cable from the NOTE: Using suitable securing straps, secure the
transaxle. engine and the transaxle on a workshop table.
1. Detach the selector lever cable from the Using suitable wooden blocks, support
selector shaft. the engine and transaxle assembly.
2. Detach the selector lever cable from the
transaxle.

40. Detach the spark plug cable retaining

bracket from the engine front mount.
37. Remove the torque converter retaining
nuts.
• Remove the cover.
• Rotate the engine to gain access to the
nuts.
• Discard the nuts.

41. Remove the engine front mount bracket

retaining nuts.
• Discard the nuts.

38. Position the workshop table under the

vehicle and carefully lower the vehicle,
until the engine and transaxle assembly
is in the correct position to remove the
engine mounts.

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303-01B-43 Engine — 2.5L 303-01B-43

REMOVAL (Continued)

46. Remove the transaxle right-hand retain-

42. Remove the engine rear mount.
ing bolts.
• Discard the nuts.

47. Remove the transaxle left-hand retaining

43. Raise and support the vehicle. For bolts.
additional information, refer to Section
100-02.
44. Remove the starter motor.

48. Remove the transaxle upper retaining

bolts.

45. Remove the transaxle lower retaining

bolts.

49. Remove the transaxle from the engine.

G88905 en 08/2002 2003.0 Mondeo

303-01B-44 Engine — 2.5L 303-01B-44

DISASSEMBLY

Engine (21 134 8)

DISASSEMBLY

Special Tool(s)
Socket, Spark Plug
Special Tool(s) 303-499 (21-202)
Flange Holding Wrench,
Universal
205-072 (15-030A)
Pliers, Valve Stem Oil Seal
303–509 (21-211)
Remover, Oil Seal
303-112 (21-051)

Name Specification

Remover, Crankshaft Oil Metal Surface Cleaner WSE-M5B392-A

Seal
303-293 (21-143)
Disassembly
1. NOTE: Inspect the oil pan drain plug seal for
Remover, Crankshaft damage. Install a new drain plug and seal if
Vibration Damper required.
303-338 (21-153B) Drain the engine oil.
• Allow the oil to drain into a suitable
container.
• Install the drain plug.
Adapter for 303-338
303-338-02 (21-153A-02)

Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

Mounting Bracket for 303-

435
303-435-06 (21-031B)

Mounting Plate for 303-435-

06
303-435-11 (21-146C)

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303-01B-45 Engine — 2.5L 303-01B-45

DISASSEMBLY (Continued)

2. Disconnect the exhaust gas recirculation 5. Install the mounting plate to the engine.
(EGR) tube from the EGR valve.
1. Disconnect the hoses.
2. Detach the tube fitting.

6. Install the mounting bracket to the mount-

ing plate.

3. CAUTION: Remove the right-hand

exhaust manifold retaining nuts in the
sequence shown.
Remove the right-hand exhaust manifold.
• Discard the gasket and the retaining nuts.

7. Mount the engine on the mounting stand.

8. Disconnect the generator electrical con-
nectors.

4. Remove the intermediate drive shaft

bracket from the cylinder block.

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303-01B-46 Engine — 2.5L 303-01B-46

DISASSEMBLY (Continued)
9. Disconnect the differential pressure feed- 12. Detach the intake manifold runner control
back EGR electrical connector. (IMRC) cable.

10. Disconnect the electronic vacuum regula- 13. Remove the IMRC actuator.
tor (EVR) solenoid valve electrical con- 1. Cut the cable ties.
nector.
2. Disconnect the IMRC electrical connector.
3. Remove the retaining bolts.

11. Disconnect the engine coolant

temperature (ECT) sensor electrical
connector.
14. Disconnect the right-hand spark plug
• Detach the wiring harness. electrical connectors.
• Detach the bracket.

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303-01B-47 Engine — 2.5L 303-01B-47

DISASSEMBLY (Continued)

15. Disconnect the left-hand spark plug 18. Disconnect the electronic vacuum
electrical connectors. regulator (EVR) hoses.
• Detach the bracket. • Remove the vacuum hose harness.

16. Remove the electronic ignition coil (EI). 19. Disconnect the positive crankcase venti-
• Disconnect the EI electrical connector. lation (PCV) hose from the throttle body.

20. Disconnect the throttle position (TP) sen-

17. Disconnect the vacuum hoses from the sor electrical connector.
upper intake manifold, the EGR valve and
the fuel pressure regulator.

G37482 en 08/2002 2003.0 Mondeo

303-01B-48 Engine — 2.5L 303-01B-48

DISASSEMBLY (Continued)
21. Disconnect the idle air control (IAC) valve 24. Disconnect the oil pressure switch elec-
electrical connector. trical connector.

22. CAUTION: Remove the upper intake 25. Disconnect the crankshaft position (CKP)
manifold retaining bolts in the sensor electrical connector.
sequence shown. • Detach the wiring harness from the retain-
ing stud.
Remove the upper intake manifold.
• Discard the gaskets.

26. Disconnect the camshaft position (CMP)

sensor electrical connector.
23. Disconnect the heated oxygen sensor
• Detach the wiring harness from the stud.
(HO2S) electrical connector.

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303-01B-49 Engine — 2.5L 303-01B-49

DISASSEMBLY (Continued)

27. Detach the wiring harness in-line electri- 30. CAUTION: Remove the lower intake
cal connectors from the mounting manifold retaining bolts in the
bracket. sequence shown.
Remove the lower intake manifold.
• Discard the gaskets.

28. Detach the wiring harness bracket from

the right-hand valve cover (two nuts).
31. Remove the coolant distribution tube.

29. Disconnect the fuel injector electrical

connectors.
• Detach the wiring harness.

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303-01B-50 Engine — 2.5L 303-01B-50

DISASSEMBLY (Continued)
32. Remove the oil level indicator and tube. 34. Remove the PCV valve and hoses.
1. Remove the retaining nut.
2. Remove the PCV and hoses.

35. Remove the coolant bypass assembly.

33. Remove the water pump drive belt.

• Rotate the belt tensioner clockwise to re-
lease the tension on the drive belt.

36. Using the special tool, disconnect the

coolant hoses from the water pump.

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303-01B-51 Engine — 2.5L 303-01B-51

DISASSEMBLY (Continued)

37. Remove the water pump. 41. Remove the generator.

• Discard the gasket.

42. Remove the generator mounting bracket.

38. Remove the clutch disc and pressure
plate.
39. Remove the flywheel.
1. Remove the flywheel retaining bolts.
2. Remove the adapter plate.

43. Remove the oil filter.

40. Using the special tool, remove the crank-

shaft rear oil seal.

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303-01B-52 Engine — 2.5L 303-01B-52

DISASSEMBLY (Continued)

44. CAUTION: Remove the left-hand 46. CAUTION: Remove the oil pan
exhaust manifold retaining nuts in the retaining bolts and studs in the
sequence shown. sequence shown.
Remove the left-hand exhaust manifold. Remove the oil pan.
• Discard the gasket and the retaining nuts. • Discard the gasket.
• Clean and inspect oil pan and cylinder
block using metal surface cleaner.

45. Remove the oil pressure switch.

47. Remove the inline connector bracket

from the valve cover.

G37482 en 08/2002 2003.0 Mondeo

303-01B-53 Engine — 2.5L 303-01B-53

DISASSEMBLY (Continued)

48. CAUTION: Remove the valve cover 50. CAUTION: Do not damage the
retaining bolts and nuts in the camshaft oil seal surface.
sequence shown.
Using the special tool, remove the
Remove the valve covers. camshaft oil seal.
• Discard the gaskets. • Discard the oil seal.

51. CAUTION: Protect the camshaft

surface when removing the oil seal
retainer.
Remove the camshaft oil seal retainer.
• Discard the gasket.

49. Using the special tools, remove the cam-

shaft pulley.

G37482 en 08/2002 2003.0 Mondeo

303-01B-54 Engine — 2.5L 303-01B-54

DISASSEMBLY (Continued)
52. Remove the power steering pump pulley. 55. Using the special tool, remove the crank-
shaft pulley.

53. Remove the power steering pump and

bracket (five bolts and six nuts). 56. Remove the CMP and CKP position sen-
sors.

54. Using the special tool, remove the

crankshaft pulley retaining bolt. 57. Using the special tool, remove the
• Discard the crankshaft pulley retaining bolt. crankshaft front oil seal.
• Discard the oil seal.

G37482 en 08/2002 2003.0 Mondeo

303-01B-55 Engine — 2.5L 303-01B-55

DISASSEMBLY (Continued)

58. NOTE: Remove the engine front cover 61. Using the special tool, remove the right-
retaining bolts and nuts in the sequence hand spark plugs.
shown.
Remove the engine front cover.
• Discard the gaskets.

62. Using the special tool, remove the left-

hand spark plugs.

59. Remove the CKP sensor pulse wheel.

63. CAUTION: Only turn the engine in the

normal direction of rotation.
60. NOTE: Do not tighten the bolt at this stage. NOTE: The crankshaft keyway will be at the 11
o'clock position when the engine is at top dead
Install the crankshaft pulley retaining center (TDC).
bolt.
Turn the engine to top dead center (TDC).
• Rotate the crankshaft keyway clockwise to
the 11 o'clock position.

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303-01B-56 Engine — 2.5L 303-01B-56

DISASSEMBLY (Continued)
66. Remove the right-hand timing chain.
64. Rotate the crankshaft until the crankshaft
keyway is in the 3 o'clock position. 1. Remove the fixed timing chain guide.
• The right-hand camshafts are in the neutral 2. Remove the right-hand timing chain.
position.

65. NOTE: Mark the position of all chain drive

components to make sure they are assembled
in their original positions.
Remove the right-hand timing chain
tensioner and timing chain tensioner arm.
1. Remove the timing chain tensioner and the
right-hand tensioner adapter plate (if
equipped).
2. Remove the timing chain tensioner arm.

G37482 en 08/2002 2003.0 Mondeo

303-01B-57 Engine — 2.5L 303-01B-57

DISASSEMBLY (Continued)

67. CAUTION: The cylinder head and the 68. Rotate the crankshaft two revolutions un-
camshaft bearing caps are numbered til the keyway is in the 11 o'clock posi-
and marked for left-hand and right- tion.
hand cylinder heads.
NOTE: Camshaft bearing caps are dowelled to
the cylinder head. If necessary, use a plastic
mallet to loosen the caps.
NOTE: Remove camshaft bearing thrust caps
No. 1R and 5R first. Do not loosen any other
retaining bolts until the thrust caps are removed.
NOTE: Loosen the retaining bolts and bearing
caps in the indicated sequence in several passes
to allow the camshafts to gradually rise from the
cylinder head.
NOTE: If the cam followers and valve tappets are
to be re-used, mark their position to make sure
they are assembled in the original location.
69. Remove the crankshaft pulley retaining
Remove the right-hand cylinder head bolt and washer.
camshafts.
• Remove the cam followers.
• Remove the valve tappets.

G37482 en 08/2002 2003.0 Mondeo

303-01B-58 Engine — 2.5L 303-01B-58

DISASSEMBLY (Continued)
70. Remove the left-hand timing chain 71. Remove the left-hand timing chain.
tensioner and timing chain tensioner arm. 1. Remove the fixed timing chain guide.
1. Remove the timing chain tensioner 2. Remove the left-hand timing chain.
retaining bolts.
2. Remove the timing chain tensioner and the
left-hand tensioner adapter plate (if
equipped).
3. Remove the timing chain tensioner arm.

G37482 en 08/2002 2003.0 Mondeo

303-01B-59 Engine — 2.5L 303-01B-59

DISASSEMBLY (Continued)

72. CAUTION: The cylinder head and the 73. CAUTION: Remove the left-hand
camshaft bearing caps are numbered cylinder head bolts in the sequence
and marked for left-hand and right- shown.
hand cylinder heads.
Remove the left-hand cylinder head.
NOTE: Remove camshaft bearing thrust caps
• Discard the gasket.
No. 1L and 5L first. Do not loosen any of the
other retaining bolts until the thrust caps are
removed.
NOTE: Loosen the retaining bolts and bearing
caps in the sequence shown in several passes to
allow the camshafts to gradually rise from the
cylinder head.
NOTE: If the cam followers and valve tappets are
to be re-used, mark their position to make sure
they are assembled in the original location.
Remove the right-hand camshafts.
• Remove the cam followers.
• Remove the valve tappets.

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303-01B-60 Engine — 2.5L 303-01B-60

DISASSEMBLY (Continued)

74. CAUTION: Remove the right-hand 76. Remove the oil separator.
cylinder head bolts in the sequence • Discard the gasket.
shown.
Remove the right-hand cylinder head.
• Discard the gaskets.

77. Remove the oil pick-up pipe.

1. Remove the retaining nut.
2. Remove the retaining bolts.
3. Remove the oil pick-up pipe.

75. Remove the power steering pump

bracket.
78. Remove the oil pan baffle.

G37482 en 08/2002 2003.0 Mondeo

303-01B-61 Engine — 2.5L 303-01B-61

DISASSEMBLY (Continued)

79. CAUTION: Remove the oil pump 81. NOTE: Before removing pistons, inspect the
retaining bolts in the sequence top of the cylinder bores. If necessary, remove
shown. the ridge from each cylinder.
NOTE: Re-attach the bearing caps to the
Remove the oil pump.
connection rods after removal.
Remove the pistons.
1. Rotate the crankshaft to position the
pistons at the top of travel.
2. Push the piston, connecting rod and upper
bearing through the top of the cylinder.

80. CAUTION: Mark the position of the

connecting rod bearing caps to the
connecting rods.
NOTE: Discard the connecting rod bolts after
removal.
Remove the connecting rod bearing caps.

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303-01B-62 Engine — 2.5L 303-01B-62

DISASSEMBLY (Continued)

82. CAUTION: Remove the lower cylinder 84. CAUTION: Avoid damage to any
block bolts in the sequence shown. crankshaft bearing surfaces.
Remove the lower cylinder block. NOTE: Never remove any pipe plugs or dowels
unless they are to be replaced or the cylinder
• Discard the retaining bolts 7 – 22.
block is to be washed.
Remove the crankshaft.
• Remove the main bearing shells.
• Discard the main bearing shells.

85. WARNING: Eye protection is required

during the use of compressed air.
Failure to follow these instructions
may result in personal injury.
Clean the cylinder block with a soap and
water solution. Dry the cylinder block
83. Remove the lower crankshaft bearings. completely with compressed air.
1. Remove the lower crankshaft main
bearings.
2. Remove the lower crankshaft thrust main
bearing.

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303-01B-63 Engine — 2.5L 303-01B-63

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head (21 165 6)

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Disassembly
Special Tool(s)
1. CAUTION: Mark the installation
Installer, Intake Valve Stem position of any valve train
Oil Seal components that are to be re-used so
303-247 (21-130A) that they are installed in the correct
position.
Using the special tools, remove the valve
Compressor, Valve Spring collets, the valve springs and the valve
spring retainers.
303-361 (21-155)

Adapter for 303-361

303-361-02 (21-155-02A)

Pliers, Valve Stem Oil Seals

303-508 (21-211)

2. Remove the valves.

Name Specification
Vehicles built up to
10/2000:
Engine oil WSS-M2C912-A1/
WSS-M2C913-A
Vehicles built 10/2000
onwards:
Engine oil WSS-M2C913-A

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303-01B-64 Engine — 2.5L 303-01B-64

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Using the special tool, remove the valve 4. Check the cylinder heads and related
stem seals. components for wear or damage. For
additional information, refer to Section
303-00.
• Discard components if damaged.

Assembly
1. WARNING: Use eye protection when
using compressed air. Failure to do so
may result in personal injury.
CAUTION: The cylinder head surface is
measured in microns. For proper head
gasket sealing, avoid any contact of the
surface with hard objects.
NOTE: Install new components if necessary.
Remove gasket material, dirt and debris
from the cylinder heads. Wash with a
suitable soap solution and dry completely
using compressed air if the blanking plugs
have been removed.
• If gasket material remains on the cylinder
head after cleaning, use a plastic scraper
to remove the remaining material.
2. Using the special tool, install new valve
stem seals.

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303-01B-65 Engine — 2.5L 303-01B-65

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Install the valves.

• Coat the valve stems and guides with en-
gine oil prior to installation.

4. Using the special tools, install the valve

spring retainers, the valve springs and the
valve collets.

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303-01B-66 Engine — 2.5L 303-01B-66

ASSEMBLY

Engine (21 134 8)

ASSEMBLY

Special Tool(s)
Adapter for 303-458
Special Tool(s) 303-458-01 (21-192-01)
Flange Holding Wrench,
Universal
205-072 (15-030A)
Installer, Crankshaft Rear Oil
Seal
303-460 (21-193A)
Installer/Aligner, Timing
Cover Oil Seal
303-055 (21-017A)

General Equipment

Remover/Installer, Suitable strap wrench

Crankshaft Vibration Damper Piston ring compressor
303-130 (21-076)
Jaw protectors

Name Specification
Angle Gauge, Bolt Tightening
Lubricant ESE-M99B176-A
303-174 (21-540)
Lubricant ESE-M1244-A (Never
Sieze)
Sealer ESE-M99B144-B
Remover/Installer, Cooling Silicone sealer WSE-M4G323-A6
Hose Clamp
Engine oil WSS-M2C913-A
303-397 (24-003)
Metal surface cleaner WSE-M5B392-A

Mounting Bracket for 303- Assembly

435
303-435-06 (21-031B) 1. CAUTION: Use only a plastic scraper
when removing old gasket material.
Clean all the mating faces and reusable
parts thoroughly and check for damage.
Mounting Plate for 303-435-
06 2. NOTE: Never remove pipe plugs or alignment
dowels unless they are to be serviced.
303-435-11 (21-146C)
Reseal oil passage blanking plugs with
sealer, as necessary.

Installer, Camshaft Pulley

303-458 (21-192)

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303-01B-67 Engine — 2.5L 303-01B-67

ASSEMBLY (Continued)

3. Select the correct crankshaft main bearing 6. NOTE: Using a suitable lever or similar tool
shells. position the crankshaft rearward before
• 11-digit codes are stamped on the rear installation of upper thrust bearings.
surface of the cylinder block and on the NOTE: Visually inspect the bearings to verify that
crankshaft flange to assist in selecting the the bearing oil holes align with the cylinder block
correct main bearing shells. For additional oil feed holes.
information, refer to Specifications in this NOTE: Align the thrust bearing locating tab to the
section. machined area on cylinder block.
4. Install the upper crankshaft bearings and
Install the lower crankshaft bearings into
thrust washer into the cylinder block.
the cylinder block.
1. Install the upper crankshaft thrust washer.
1. Install the lower crankshaft thrust bearing
2. Install the upper crankshaft main bearing into the lower cylinder block.
shells. 2. Install the lower crankshaft main bearing
• Lubricate the bearing shells and thrust shells into the lower cylinder block.
washer with clean engine oil.
• Lubricate the bearing shells and the thrust
washer with clean Engine oil.

5. Install the crankshaft.

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303-01B-68 Engine — 2.5L 303-01B-68

ASSEMBLY (Continued)

7. NOTE: Silicone sealer application must stop 6 8. CAUTION: Make sure all the dowels are
mm from the rear crankshaft bore on each fully seated into the lower cylinder
side. block before tightening the retaining
NOTE: The lower cylinder block should be bolts.
installed and tightened to specification within six
minutes of applying sealer. CAUTION: Do not lubricate the lower
cylinder block bolts.
Apply a bead of sealer to the cylinder
block housing. CAUTION: Tighten the lower cylinder
• Apply a 3 mm bead to area shown. block bolts in the sequence shown.
• Apply a 1 mm bead to area shown. CAUTION: Do not rotate the crankshaft
until all retaining bolts are tightened to
specification.
NOTE: Before installing the retaining bolts use a
lever or similar tool to lightly seat the crankshaft
forward.
NOTE: Install new retaining bolts in locations 1-
16.
Position the lower cylinder block on the
upper cylinder block.
• Gently lever the crankshaft rearward to
seat the crankshaft thrust washer.

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303-01B-69 Engine — 2.5L 303-01B-69

ASSEMBLY (Continued)

9. CAUTION: Install new lower cylinder 12. CAUTION: Install the pistons with the
block bolts in locations 1-16. arrow to front of the engine.
Install the lower cylinder block bolts. Using a suitable piston ring compressor,
• Tighten the lower cylinder block bolts in the install the pistons.
sequence shown. • Lubricate the piston and connecting rod
• Bolts 1-8, 25 Nm bearing with clean engine oil before instal-
lation.
• Bolts 9-16, 40 Nm
• Bolts 1-16, 90 degrees
• Bolts 17-22, 25 Nm
• Check that the crankshaft rotates freely.

13. CAUTION: Make sure that the bearing

location tangs of the connecting rod
and bearing cap are on the same side.
CAUTION: Install new connecting rod
retaining bolts.
Install the connecting rod bearing caps.
• Tighten the bolts in three stages:
• Stage 1: 23 Nm
• Stage 2: 43 Nm
• Stage 3: 90 degrees

10. Remove excess sealer which may

squeeze out of the front cover sealing
surface.
11. Rotate the crankshaft until the bearing
journal at bottom dead center (BDC).

14. Check the connecting rod side clearance.

For additional information, refer to
Section 303-00.
15. Rotate the crankshaft to make sure the
crankshaft and pistons operate freely.

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303-01B-70 Engine — 2.5L 303-01B-70

ASSEMBLY (Continued)

16. Install the oil pump. 18. NOTE: Apply O-ring lubricant to the O-ring
• Tighten the bolts in the sequence shown. before installation.
Install the oil pick-up pipe retaining nut.
• Tighten the nut in two stages.
• Stage 1: 5 Nm
• Stage 2: 45 degrees

17. Install the oil pan baffle.

• Tighten the bolts in two stages.
• Stage 1: 5 Nm
• Stage 2: 45 degrees

19. Install the oil pick-up pipe retaining bolts.

20. NOTE: Install a new oil separator gasket.

Install the oil separator.

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303-01B-71 Engine — 2.5L 303-01B-71

ASSEMBLY (Continued)

21. Install the power steering pump bracket. 22. NOTE: Install a new cylinder head gasket.
• Align the bracket with the locating dowels. NOTE: Left-hand and right-hand cylinder head
gaskets are not interchangeable.
NOTE: Install new cylinder head bolts with
washers.
Install the left-hand cylinder head.
• Align the cylinder head with the locating
dowels.
• Tighten the bolts in the sequence shown in
two stages.
• Stage 1: 40 Nm
• Stage 2: 90 degrees

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303-01B-72 Engine — 2.5L 303-01B-72

ASSEMBLY (Continued)
23. Loosen the left-hand cylinder head bolts. 24. Tighten the left-hand cylinder head bolts
• Loosen the cylinder head bolts in the se- in the sequence shown in three stages.
quence shown one turn. • Stage 1: 40 Nm
• Stage 2: 90 degrees
• Stage 3: 90 degrees

25. Check all camshaft specifications. For

additional information, refer to Section
303-00.
26. Install the crankshaft pulley washer and
retaining bolt.

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303-01B-73 Engine — 2.5L 303-01B-73

ASSEMBLY (Continued)

27. NOTE: Install a new cylinder head gasket. 28. Loosen the right-hand cylinder head
NOTE: Left-hand and right-hand cylinder head bolts.
gaskets are not interchangeable. • Loosen the cylinder head bolts in the se-
NOTE: Install new cylinder head bolts with quence shown one turn.
washers.
Install the right-hand cylinder head.
• Align the cylinder head with the locating
dowels.
• Tighten the bolts in the sequence shown in
two stages.
• Stage 1: 40 Nm
• Stage 2: 90 degrees

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303-01B-74 Engine — 2.5L 303-01B-74

ASSEMBLY (Continued)
29. Tighten the right-hand cylinder head 31. Install the valve tappets to the left-hand
bolts in the sequence shown in three cylinder head.
stages. • Lubricate the valve tappets with clean en-
• Stage 1: 40 Nm gine oil before installation.
• Stage 2: 90 degrees
• Stage 3: 90 degrees

30. Rotate the crankshaft until the keyway is

in the 11 o'clock position.

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303-01B-75 Engine — 2.5L 303-01B-75

ASSEMBLY (Continued)

32. Install the left-hand camshafts. 34. Install the valve tappets to the right-hand
• Lubricate the camshafts with clean engine cylinder head.
oil. • Lubricate the valve tappets with clean en-
gine oil before installation.
33. CAUTION: Do not install thrust caps
1L and 5L at this time, or damage to
the thrust caps may occur.
NOTE: Do not tighten the camshaft cap retaining
bolts at this stage.
Install the left-hand camshaft caps in
their original positions.

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303-01B-76 Engine — 2.5L 303-01B-76

ASSEMBLY (Continued)
35. Install the right-hand camshafts.
38. NOTE: The colored links of the timing chain
• Lubricate the camshafts with clean engine and the marks on the timing sprockets must
oil before installation. be aligned.
36. CAUTION: Do not install thrust caps Install the left-hand timing chain.
5R and 1R at this time or damage to 1. Install the left-hand timing chain guide.
the thrust caps may result.
2. Install the crankshaft sprockets.
NOTE: Do not tighten the camshaft cap retaining
3. Install the timing chain.
bolts of this stage.
Install the right-hand camshaft caps in
their original positions.

39. Using suitable jaw protector, loosely grip

the left-hand timing chain tensioner in a
vise.
37. Remove the crankshaft pulley retaining
bolt and washer.

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303-01B-77 Engine — 2.5L 303-01B-77

ASSEMBLY (Continued)

40. CAUTION: During tensioner 43. Install the left-hand timing chain
compression, do not release the tensioner.
ratchet stem until the tensioner piston 1. Install the left-hand timing chain tensioner
is fully bottomed in its bore or damage arm.
to the ratchet stem will result. 2. Install the left-hand timing chain tensioner
Install a suitable pin. adapter plate, the timing chain tensioner
and retaining bolts.

41. NOTE: The piston should retract with minimal

force. If binding occurs, reposition the
tensioner to eliminate side loading.
Slowly compress the left-hand timing
chain tensioner, by tightening the vise.
42. NOTE: The retaining wire must remain in the
timing chain tensioner until the tensioner is
installed into the engine with the piston
bottomed in the bore.
Retain piston with a 1.5 mm diameter wire
or paper clip.

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303-01B-78 Engine — 2.5L 303-01B-78

ASSEMBLY (Continued)

44. NOTE: The colored links of the timing chain 46. CAUTION: During tensioner
and the marks on the sprocket must be compression, do not release the
aligned. ratchet stem until the tensioner piston
Install the right-hand timing chain. is fully bottomed in its bore, or
1. Install the right-hand timing chain guide. damage to the ratchet stem will result.
2. Install the timing chain. Install a suitable pin.

47. NOTE: The piston should retract with minimal

force. If binding occurs, reposition the
tensioner to eliminate side loading.
Slowly compress the right-hand timing
chain tensioner, by tightening the vise.
48. NOTE: The retaining wire must remain in the
timing chain tensioner until the tensioner is
installed into the engine with the piston
bottomed in the bore.
Retain piston with a 1.5 mm diameter wire
or paper clip.

45. Using a suitable jaw protector, loosely

grip the right-hand timing chain tensioner
in a vise.

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303-01B-79 Engine — 2.5L 303-01B-79

ASSEMBLY (Continued)

49. Install the right-hand timing chain 50. NOTE: Ignore the timing flags on the rear of
tensioner. the camshaft sprockets.
1. Install the timing chain tensioner arm. NOTE: Check the number of timing chain links
2. Install the right-hand timing chain tensioner between the camshaft front timing marks and the
adapter plate, the timing chain tensioner timing marks on the crankshaft sprockets.
and retaining bolts. Check the camshaft timing.
1. 10 links.
2. 23 links.
3. 25 links.

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303-01B-80 Engine — 2.5L 303-01B-80

ASSEMBLY (Continued)

51. CAUTION: The crankshaft keyway 52. CAUTION: Do not install the left-hand
must be in the 11 o'clock position cylinder head camshaft journal thrust
before installation of the left-hand caps until the camshaft journal caps
cylinder head cam followers. are installed or damage to the thrust
NOTE: Check that all the timing marks and caps may occur.
reference flags are in the correct position before NOTE: With left-hand cylinder head cam
installing the cam followers. followers installed, align camshaft end play using
NOTE: The cam followers must be installed in thrust caps as a guide before tightening the
their original positions. journal caps.
Install the left-hand cylinder head cam Tighten the left-hand camshaft bearing
followers. cap retaining bolts.
• Lubricate the cam followers with clean en- • Tighten the bolts in the sequence shown in
gine oil before installation. several stages.

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303-01B-81 Engine — 2.5L 303-01B-81

ASSEMBLY (Continued)

53. CAUTION: Only turn the engine in the 55. CAUTION: Do not install the right-
normal direction of rotation. hand cylinder head camshaft journal
thrust caps until the camshaft journal
Rotate the crankshaft until the keyway is
caps are installed, or damage to the
in the 3 o'clock position.
thrust caps may occur.
NOTE: With right-hand cylinder head cam
followers installed, align camshaft end play using
the thrust caps as a guide before tightening
journal caps.
Tighten the right-hand camshaft bearing
cap retaining bolts.
• Tighten the bolts in the sequence shown in
several stages.

54. CAUTION: The crankshaft keyway

must be in the 3 o'clock position
before installation of the right-hand
cylinder head cam followers. Failure
to do so may lead to engine damage.
NOTE: The cam followers must be installed in
their original locations.
Install the right-hand cylinder head cam
followers.
• Lubricate the cam followers with clean en-
gine oil before installation.

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303-01B-82 Engine — 2.5L 303-01B-82

ASSEMBLY (Continued)

56. Remove the iming chain tensioner retain- 58. NOTE: Install the engine front cover within six
ing wires on both sides. minutes of applying the sealer.
Apply a 6 mm dot of sealer to the mating
faces in the positions shown.

57. CAUTION: The pulse wheel has two

keyway slots and is used in several
different engines.
Install the pulse wheel in the keyway slot 59. CAUTION: The engine front cover
stamped 25, color coded blue. must be installed in two stages.
NOTE: Install new engine front cover gaskets.
Install the engine front cover.
• Note locating dowels and the locations of
the studs.
• Install the engine front cover retaining bolts
and studs in the sequence shown.
• Tighten the retaining bolts and studs one-
quarter turn after engine front cover con-
tacts cylinder block and cylinder heads.

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303-01B-83 Engine — 2.5L 303-01B-83

ASSEMBLY (Continued)

60. NOTE: 3, 4, 8, 10, 11, 14, 15,16 are stud 62. Using the special tools, install the
locations. crankshaft front oil seal.
Install the remaining engine front cover • Lubricate the outer ring with clean engine
retaining bolts and studs. oil before installation.
• Tighten the bolts and studs in the se-
quence shown.

63. Apply sealer to the front of the

crankshaft on the inside diameter surface
of the crankshaft pulley at the keyway.
61. Install the crankshaft position sensor
(CKP), the camshaft position sensor • Before applying the sealer, clean the
(CMP) and wiring brackets. sealing surfaces with metal surface
cleaner to remove all residues.
• Lubricate the O-ring with sealer before in-
stallation. 64. NOTE: Use the crankshaft pulley retaining
bolt washer for installation.
Using the special tool, install the crank-
shaft pulley.

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303-01B-84 Engine — 2.5L 303-01B-84

ASSEMBLY (Continued)

65. CAUTION: Install a new crankshaft 67. NOTE: The longer 84 mm retaining bolts
pulley retaining bolt. should be tightened first.
Using the special tool, install the Tighten the 84 mm power steering pump
crankshaft pulley. retaining bolts.
• Tighten the bolt in four stages.
• Stage 1: 120 Nm
• Stage 2: Loosen one turn
• Stage 3: 50 Nm
• Stage 4: 90 degrees

68. Tighten the power steering pump retain-

ing nuts.

66. NOTE: Do not tighten the power steering

pump bracket retaining bolts and studs at this
stage.
Install the power steering pump and
bracket.

69. NOTE: The dimple on the pulley must face

toward the front of the engine.
Install the power steering pump belt pul-
ley.

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303-01B-85 Engine — 2.5L 303-01B-85

ASSEMBLY (Continued)

70. NOTE: Install a new gasket.

73. Using the special tool, install the left-
Install the camshaft oil seal retainer. hand spark plugs.
• Align the retainer on the locating dowels
and tighten the retaining bolts.

74. Using the special tool, install the right-

hand spark plugs.
71. CAUTION: The running surface of the
camshaft must not be damaged.
Using the special tools, install the
camshaft oil seal.
• Lubricate the camshaft oil seal with clean
engine oil before installation.

75. Apply silicone sealer to the mating faces

of the cylinder heads.

72. Using the special tool, install the water

pump drive pulley.

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303-01B-86 Engine — 2.5L 303-01B-86

ASSEMBLY (Continued)
76. NOTE: Install new gaskets. 78. NOTE: Install the oil pan within six minutes of
applying the sealer.
Install the valve covers.
• Tighten the valve cover retaining bolts in Apply a 10 mm bead of sealer onto the
the sequence shown. cylinder block at the indicated areas.

79. NOTE: Note the locations of the studs.

Install the oil pan.
• Tighten the bolts in the sequence shown.

77. Install the wiring harness in-line electrical

connector retaining bracket to the valve
cover.

80. Install the oil pressure switch (high out-

put engine shown).

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303-01B-87 Engine — 2.5L 303-01B-87

ASSEMBLY (Continued)

81. NOTE: If studs were removed, install short

84. Install the generator mounting bracket.
end of studs into the cylinder head.
NOTE: Install a new gasket and retaining nuts.
Install the left-hand exhaust manifold.
• Tighten the nuts in the sequence shown.

85. Install the generator.

82. Install a new oil filter.

86. CAUTION: Tighten the bolts in several

stages to correctly seat the crankshaft
rear oil seal until it is flush with the
cylinder block.
83. NOTE: If studs were removed, install short Using the special tool, install the
end of studs into the cylinder head. crankshaft rear oil seal.
NOTE: Install a new gasket and retaining nuts. • Lubricate the outer ring with clean engine
Install the right-hand exhaust manifold. oil before installation.
• Tighten the nuts in the sequence shown.

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303-01B-88 Engine — 2.5L 303-01B-88

ASSEMBLY (Continued)
87. NOTE: Use a suitable strap wrench to hold 89. Using the special tool, connect the water
the crankshaft pulley. pump coolant hoses to the water pump.
Install the flywheel.
1. Install the adapter plate.
2. Install the flywheel.
• Tighten the bolts in the sequence shown.

90. NOTE: Install new O-ring seals.

Install the cooling system bypass
assembly.
• Lubricate the O-ring seals with sealer be-
88. NOTE: Install a new gasket. fore installation.
Install the water pump.
• Tighten the bolts in two stages.
• Stage 1: 10 Nm
• Stage 2: 90 degrees

91. Install the positive crankcase ventilation

(PCV) valve and hoses.
1. Connect the PCV valve and hoses.
2. Install the bracket retaining nut.

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303-01B-89 Engine — 2.5L 303-01B-89

ASSEMBLY (Continued)

92. Install the water pump drive belt. 94. Install the coolant distribution tube.
• Rotate the belt tensioner clockwise to re-
lease the tension on the belt.

95. Using the special tool, connect the cool-

ant hoses.
93. NOTE: Install the O-ring seal on the oil level
indicator tube and lubricate with clean engine
oil before installation.
Install the oil level indicator tube.
• Locate the oil level indicator tube using a
twisting motion.

96. CAUTION: Install new gaskets with

the locating lugs facing downwards.
Install the lower intake manifold.
• Tighten the bolts in the sequence shown.

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303-01B-90 Engine — 2.5L 303-01B-90

ASSEMBLY (Continued)
97. Connect the fuel injector electrical con- 100. Connect the oil pressure switch elec-
nectors. trical connector.

98. Connect the CKP sensor electrical 101. Connect the heated oxygen sensor
connector. (HO2S) electrical connector.
• Attach the wiring harness to the retaining
stud.

102. CAUTION: Install new gaskets with

the locating lugs pointing downwards.

99. Connect the CMP sensor electrical Install the upper intake manifold.
connector. • Tighten the bolts in the sequence shown.
• Attach the wiring harness to the retaining
stud.

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303-01B-91 Engine — 2.5L 303-01B-91

ASSEMBLY (Continued)

103. Connect the throttle position (TP) sen- 106. Connect the vacuum lines to the
sor electrical connector. electronic vacuum regulator (EVR).
• Install the vacuum harness.

104. Connect the PCV hose to the throttle

body. 107. Connect the vacuum hoses to the up-
per intake manifold, the EGR valve and
the fuel pressure regulator.

105. Connect the idle air control (IAC) valve

electrical connector.

108. Install the electronic ignition (EI) coil.

• Install the EI coil, make sure the radio sup-
pressor and ground cable are connected.
Connect the EI coil electrical connector.

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303-01B-92 Engine — 2.5L 303-01B-92

ASSEMBLY (Continued)
109. Connect the left-hand spark plug elec- 111. Install the intake manifold runner
trical connectors. control (IMRC) actuator and mounting
bracket.
1. Tighten the IMRC actuator bracket
retaining bolts.
2. Connect the electrical connector.
3. Install a new cable tie.

110. Connect the right-hand spark plug

electrical connectors.
• Attach the wiring harness to the engine
mount.

112. Attach the IMRC cable to the throttle

body.

113. Attach the wiring harness bracket to

the right-hand valve cover (two nuts).

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303-01B-93 Engine — 2.5L 303-01B-93

ASSEMBLY (Continued)

114. Attach the wiring harness in-line elec- 117. Connect the generator electrical con-
trical connectors to the mounting nectors.
bracket.

118. Using a suitable engine hoist, remove

115. Connect the EVR solenoid valve elec- the engine from the mounting stand.
trical connector. 119. Remove the special tools.

116. Connect the differential pressure feed-

back EGR electrical connector. 120. Install the intermediate shaft bracket to
the cylinder block.

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303-01B-94 Engine — 2.5L 303-01B-94

ASSEMBLY (Continued)
121. NOTE: Install a new gasket and retaining
nuts.
Install the right-hand exhaust manifold.
• Tighten the nuts in the sequence shown.

122. Connect the EGR pipe to the EGR

valve.
1. Attach the pipe fitting.
2. Connect the hoses.

123. Fill the engine with clean engine oil .

124. Install the clutch disc and pressure
plate.

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303-01B-95 Engine — 2.5L 303-01B-95

INSTALLATION

Engine — Vehicles With: Automatic Transaxle

INSTALLATION

1. CAUTION: The torque converter hub

must engage fully in the oil pump
Special Tool(s) drive gear.

Remover/Installer Cooling Check the installation depth of the torque

Hose Clamp converter.
303-397 (24-003) 1. Lay a steel straightedge across the
automatic transaxle flange.
2. Check the installation depth between the
steel straight edge and the drive plate stud.
• Apply a thin layer of high-temperature
General Equipment
grease to the centering spigot on the
Workshop table torque converter.
Securing straps
Engine hoist
Steel straight edge

Name Specification
High temperature
grease
Grease, inner tripode WSD-M1C230-A
joint

Installation
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 ignite.
Failure to follow these instructions may
result in personal injury.

2. NOTE: Do not support directly on the oil pan.

Using suitable securing straps, secure the
engine to the workshop table.
Install the transaxle to the engine.

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303-01B-96 Engine — 2.5L 303-01B-96

INSTALLATION (Continued)
3. Install the transaxle upper retaining bolts.
6. Install the transaxle lower retaining bolts.

4. Install the transaxle left-hand retaining

7. Install the starter motor.
bolts.

8. Using wooden blocks and a securing

5. Install the transaxle right-hand retaining
strap, support the engine and transaxle
bolts.
assembly on the workshop table.
9. Remove the engine hoist.
10. Position the workshop table under the
vehicle and carefully lower the vehicle,
until the engine and transaxle assembly
is in the correct position to install the en-
gine mounts.

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303-01B-97 Engine — 2.5L 303-01B-97

INSTALLATION

11. NOTE: Install new engine rear mount 14. Raise and support the vehicle. For
retaining nuts. additional information, refer to Section
NOTE: Do not fully tighten the engine rear mount 100-02.
retaining nuts at this stage. 15. NOTE: Install new torque converter retaining
nuts.
Install the engine rear mount.
Install the torque converter retaining
nuts.
• Rotate the engine to gain access to the
nuts.
• Install the cover.

12. NOTE: Install new engine front mount bracket

retaining nuts.
NOTE: Do not fully tighten the engine front mount
bracket retaining nuts at this stage.
Install the engine front mount bracket.
16. Attach the air conditioning (A/C) com-
pressor to the mounting bracket.

13. Remove the securing straps.

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303-01B-98 Engine — 2.5L 303-01B-98

INSTALLATION (Continued)
17. Connect the A/C compressor electrical 20. Using the special tool, connect the lower
connector. coolant hose to the radiator.

18. Connect the transaxle electrical connec- 21. CAUTION: Support the halfshaft. The
tors. inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
CAUTION: Make sure the snap ring is
correctly seated.
NOTE: Install a new snap ring.
NOTE: Install a new O-ring seal.
Attach the left-hand halfshaft to the
transaxle.

19. Connect the fluid cooler pipes to the

transaxle.

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303-01B-99 Engine — 2.5L 303-01B-99

INSTALLATION (Continued)

22. CAUTION: Support the halfshaft. The 25. Install the selector lever cable cover.
inner joint must not be bent more than
18 degrees. The outer joint must not
be bent at more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
NOTE: Install a new center bearing cap and new
retaining nuts.
NOTE: Install a new O-ring seal.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.

26. Lower the vehicle.

27. Tighten the engine rear mount retaining
nuts.

23. Install the subframe. For additional

information, refer to Section 502-00.
24. NOTE: Make sure the transaxle selector lever
is in "P" (PARK) position.
Connect the selector lever cable to the
transaxle.
28. Tighten the engine front mount bracket
1. Attach the selector lever cable to the retaining nuts and bolt.
selector lever.
2. Attach the selector lever cable to the selec-
tor shaft.

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303-01B-100 Engine — 2.5L 303-01B-100

INSTALLATION (Continued)
29. Attach the spark plug cable retaining 32. Connect the power steering pipe.
bracket to the engine front mount. • Install the clip.

30. Attach the power steering reservoir to the 33. Attach the power steering line support
radiator grille opening panel. bracket to the engine front mount.

31. Using the special tool, connect the power 34. Connect the starter motor electrical con-
steering pump supply hose to the power nectors.
steering pump.

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303-01B-101 Engine — 2.5L 303-01B-101

INSTALLATION (Continued)

35. Connect the ground cable to the trans- 38. Connect the heated oxygen sensor
axle. (HO2S) electrical connector.

36. Connect the engine wiring harness elec- 39. Install the electronic ignition (EI) coil to
trical connectors. the right-hand valve cover.

37. Attach the engine wiring harness to the 40. Connect the EI electrical connectors.
right-hand valve cover.

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303-01B-102 Engine — 2.5L 303-01B-102

INSTALLATION (Continued)
41. Attach the evaporative emissions (EVAP) 44. Attach the accelerator cable.
solenoid valve to the intake manifold. • Attach the clips and the accelerator cable
to the bracket.

42. Using the special tool, connect the cool-

ant hose to the coolant expansion tank. 45. Install the accessory drive belt. For
additional information, refer to Section
303-05.
46. Connect the fuel supply line. For addi-
tional information, refer to Section 310-
00.

43. Using the special tool, connect the cool-

ant hoses to the coolant connecting pipe.

47. Adjust the selector lever cable. For

additional information, refer to Section
307-05A / 307-05B.

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303-01B-103 Engine — 2.5L 303-01B-103

INSTALLATION (Continued)

48. Attach the brake booster vacuum pipe to 51. Tighten the strut and spring assembly
the intake manifold. top mount retaining nuts on both sides.

49. Install the air cleaner. 52. Install the strut and spring assembly top
1. Attach the air cleaner outlet hose clamp. mount brace cover on both sides.
2. Connect the positive crankcase ventilation
(PCV) hoses.
3. Connect the mass air flow (MAF) sensor
electrical connector.

53. Connect the battery ground cable. For

additional information, refer to Section
414-01.
54. Fill the cooling system. For additional
information, refer to Section 303-03.
50. Install the engine upper cover.
55. Fill and bleed the power steering system.
For additional information, refer to
Section 211-00.
56. Initialize the door window motors. For
additional information, refer to Section
501-11.

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303-03-1 Engine Cooling 303-03-1

SECTION 303-03 Engine Cooling

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-03-2

DESCRIPTION AND OPERATION

Engine Cooling .................................................................................................................. 303-03-4

DIAGNOSIS AND TESTING

Engine Cooling .................................................................................................................. 303-03-8

Inspection and Verification ............................................................................................... 303-03-8
Symptom Chart ................................................................................................................ 303-03-8
Component Tests ............................................................................................................. 303-03-12

GENERAL PROCEDURES

Cooling System Draining, Filling and Bleeding — 1.8L/2.0L ......................... (24 122 0) 303-03-14
Cooling System Draining, Filling and Bleeding — 2.5L/3.0L ......................... (24 122 0) 303-03-15

REMOVAL AND INSTALLATION

Thermostat Housing — 1.8L/2.0L ................................................................. (24 001 0) 303-03-16

Thermostat — 2.5L/3.0L ............................................................................... (24 454 0) 303-03-18
Water Pump — 1.8L/2.0L ............................................................................. (24 404 0) 303-03-20
Water Pump — 2.5L/3.0L ............................................................................. (24 404 0) 303-03-21
Radiator........................................................................................................ (24 254 0) 303-03-23
Cooling Fan Motor and Shroud — 1.8L/2.0L/2.5L, Vehicles With: Manual (24 222 0)
Transaxle/4-Speed Automatic Transaxle/5-Speed Automatic Transaxle ..... 303-03-25
Coolant Outlet Connector — 1.8L/2.0L .............................................................................. 303-03-27
Bypass Tube — 2.5L/3.0L ................................................................................................. 303-03-29

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303-03-2 Engine Cooling 303-03-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Motorcraft Super Plus 2000 WSS-M97B44–D

Antifreeze
Specific Gravity Approximate
(providing no other percentage of Anti-
additive is in coolant) Freeze (by volume) Remains Fluid to Solidifies at
1.061 at +15°C 50% –25°C (–13°F) –30°C (–22°F)

Cooling System Refill Capacities

Description Liters
Cooling system and heater - Vehicles with 1.8L engine 8.3
Cooling system and heater - Vehicles with 2.0L engine 8.1
Cooling system and heater - Vehicles with 2.5L engine and manual transaxle 9.5
Cooling system and heater - Vehicles with 2.5L engine and automatic transaxle 9.7
Cooling system and heater - Vehicles with 3.0L engine and manual transaxle 9.7
Cooling system, heater and fuel fired heater - Vehicles with 2.0L diesel engine 10.4
Cooling system, heater and supplementary heater - Vehicles with 2.0L diesel 10.6
engine

Cooling System Pressure Specification

Description Pressure kpa (psi)
Radiator pressure test 138 (20)
Coolant expansion tank cap release pressure 130 to 150 (18 to 21)

Torque Specifications
Description Nm lb-ft lb-in
Air conditioning condenser retaining bolts 10 - 89
Radiator support bracket retaining bolts 10 - 89
Thermostat housing retaining bolts - Vehicles with 10 - 89
1.8L or 2.0L engine
Thermostat housing retaining bolts - Vehicles with 18 13 -
2.5L or 3.0L engine
Thermostat housing retaining bolts - Vehicles with 23 17 -
2.0L diesel engine
Water pump pulley retaining bolts - Vehicles with 25 18 -
1.8L or 2.0L engine
Water pump retaining bolts - Vehicles with 1.8L or 10 - 89
2.0L engine
Water pump retaining bolts - Vehicles with 2.5L or 10 - 89
3.0L engine
Water pump retaining nut and bolts - Vehicles with 24 18 -
2.0L diesel engine
Engine oil temperature control thermostat retaining 10 - 89
bolt - Vehicles with 2.0L diesel engine
Water pump housing retaining bolts - Vehicles with 10 - 89
2.0L diesel engine
Power steering pump supply line bracket retaining 8 - 71
nut.

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303-03-3 Engine Cooling 303-03-3

SPECIFICATIONS (Continued)

Description Nm lb-ft lb-in

Bypass tube retaining bolts - Vehicles with 2.5L or 10 - 89
3.0L engine

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303-03-4 Engine Cooling 303-03-4

DESCRIPTION AND OPERATION

Engine Cooling
DESCRIPTION AND OPERATION

Vehicles with 1.8L or 2.0L engine

Item Part Description

Item Part Description Number
Number
2 - Thermostat
1 - Coolant expansion tank
3 - Water pump

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303-03-5 Engine Cooling 303-03-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
4 - Cooling fan motor and 5 - Radiator
shroud

Vehicles with 2.5L engine

Item Part Description

Number
1 - Coolant expansion tank

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303-03-6 Engine Cooling 303-03-6

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
2 - Thermostat 4 - Radiator
3 - Water pump 5 - Cooling fan motor and
shroud

Vehicles with diesel engine

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303-03-7 Engine Cooling 303-03-7

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
1 - Coolant expansion tank
2 - Thermostat
3 - Water pump
4 - Radiator
5 - Cooling fan motor and
shroud

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303-03-8 Engine Cooling 303-03-8

DIAGNOSIS AND TESTING

Engine Cooling
DIAGNOSIS AND TESTING

Mechanical Electrical
– Coolant leak(s) – Fuse(s)
Special Tool(s) – Gaskets or seals – Wiring harness
– Hose(s) or hose – Electrical
Pressure Tester, Cooling joints connector(s)
System
– Coolant expansion – Engine coolant
303-396 (24-001 A) tank pressure cap temperature (ECT)
and seal sensor
– Coolant expansion – Cylinder head
Adapter for 303-396 tank temperature (CHT)
303-396-01 – Radiator sensor
– Water pump – Powertrain control
module (PCM)
– Thermostat
– Accessory drive belt
- all except vehicles
with 2.0L diesel
Inspection and Verification engine
1. Verify the customer concern. – Power steering
pump belt - vehicles
2. Visually inspect for obvious signs of with 2.0L diesel
mechanical or electrical damage. engine
– Exhaust gas
Visual Inspection Chart recirculation (EGR)
cooler - vehicles
with 2.0L diesel
engine
– Engine oil cooler -
vehicles with 2.0L
diesel engine
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Loss of coolant • Hose(s) or hose joint(s). • INSPECT the hoses and hose
joints. INSTALL a new hose(s)
as necessary.
• Radiator. • INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as nec-
essary. REFER to Radiator in
this section.

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303-03-9 Engine Cooling 303-03-9

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Water pump. • INSPECT the water pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new wa-
ter pump or water pump gasket
as necessary. REFER to Water
Pump - vehicles with 1.8L or
2.0L engine / Water Pump - ve-
hicles with 2.5L or 3.0L engine
in this section.
• Thermostat housing. • INSPECT the thermostat hous-
ing for leaks. CARRY OUT the
Pressure Test Component Test
in this section. INSTALL a new
thermostat housing and thermo-
stat housing gasket as neces-
sary. REFER to Thermostat
Housing - vehicles with 1.8L or
2.0L engine / Thermostat - vehi-
cles with 2.5L or 3.0L engine in
this section.
• Coolant expansion tank pres- • CARRY OUT the Coolant Ex-
sure cap or seal. pansion Tank Pressure Cap
Pressure Test Component Test
in this section.
• Coolant expansion tank. • INSPECT the coolant expansion
tank for damage. INSTALL a
new coolant expansion tank as
necessary.
• Exhaust gas recirculation (EGR) • INSPECT the EGR cooler for
cooler - vehicles with 2.0L diesel leaks. CARRY OUT the Pres-
engine. sure Test Component Test in
this section. INSTALL a new
EGR cooler as necessary.
REFER to Section 303-08B.
• Engine oil cooler - vehicles with • INSPECT the engine oil cooler
2.0L diesel engine. for leaks. CARRY OUT the
Pressure Test Component Test
in this section. INSTALL a new
engine oil cooler as necessary.
• Heater core. • CHECK the heater core for
leaks.
• Engine. • INSPECT the engine, cylinder
head, cylinder block and cylin-
der head gasket. REFER to
Section 303-00.

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303-03-10 Engine Cooling 303-03-10

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• The engine overheats (signs of • Cooling system does not hold • CARRY OUT the Coolant
coolant boiling) pressure. Expansion Tank Pressure Cap
Pressure Test Component Test
in this section.
– INSPECT the coolant
expansion tank for damage.
INSTALL a new coolant
expansion tank as
necessary.
– INSPECT the water pump or
water pump gasket for
damage. INSTALL a new
water pump or water pump
gasket as necessary.
REFER to Water Pump -
vehicles with 1.8L or 2.0L
engine / Water Pump -
vehicles with 2.5L or 3.0L
engine in this section.
– INSPECT the engine, cylin-
der head, cylinder block and
cylinder head gasket.
REFER to Section 303-00.
• Air in system. • BLEED the cooling system.
REFER to Cooling System
Draining, Filling and Bleeding -
vehicles with 1.8L or 2.0L en-
gine / Cooling System Draining,
Filling and Bleeding - vehicles
with 2.5L or 3.0L engine in this
section.
• Coolant expansion tank pres- • CARRY OUT the Coolant Ex-
sure cap or seal. pansion Tank Pressure Cap
Pressure Test Component Test
in this section.
• Coolant expansion tank. • INSPECT the coolant expansion
tank for damage. INSTALL a
new coolant expansion tank as
necessary.

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303-03-11 Engine Cooling 303-03-11

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Coolant level or condition. • CHECK the coolant level.
REFILL the cooling system as
necessary. REFER to Cooling
System Draining, Filling and
Bleeding - vehicles with 1.8L or
2.0L engine / Cooling System
Draining, Filling and Bleeding -
vehicles with 2.5L or 3.0L
engine in this section.
• CHECK the coolant condition. If
the coolant is in poor condition
drain and refill with new coolant.
REFER to Cooling System
Draining, Filling and Bleeding -
vehicles with 1.8L or 2.0L en-
gine / Cooling System Draining,
Filling and Bleeding - vehicles
with 2.5L or 3.0L engine in this
section.
• Coolant concentration. • REFER to Specifications in this
section.
• Radiator grille. • INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
• Water pump. • CARRY OUT the Pressure Test
Component Test in this section.
INSPECT the water pump for
leaks. INSTALL a new water
pump or water pump gasket as
necessary. REFER to Water
Pump - vehicles with 1.8L or
2.0L engine / Water Pump - ve-
hicles with 2.5L or 3.0L engine
in this section.
• Thermostat. • CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary. REFER
to Thermostat Housing - vehi-
cles with 1.8L or 2.0L engine /
Thermostat - vehicles with 2.5L
or 3.0L engine in this section.
• Accessory drive belt - all except • CHECK the accessory drive belt
vehicles with 2.0L diesel engine. for correct operation. REFER to
Section 303-05.
• Power steering pump belt - ve- • CHECK the power steering
hicles with 2.0L diesel engine. pump belt for correct operation.
REFER to Section 303-05.

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303-03-12 Engine Cooling 303-03-12

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Cooling fan. • CHECK the operation of the
cooling fan. REFER to WDS.
• Engine. • INSPECT the engine, cylinder
head, cylinder block and cylin-
der head gasket. REFER to
Section 303-00.
• The engine does not reach nor- • Thermostat. • CARRY OUT the Thermostat
mal operating temperature. Test Component Test in this
section. INSTALL a new ther-
mostat as necessary. REFER
to Thermostat Housing - vehi-
cles with 1.8L or 2.0L engine /
Thermostat - vehicles with 2.5L
or 3.0L engine in this section.
Section 303-00. Drain the cooling system,
repair any coolant leaks found and fill and
Component Tests bleed the cooling system as necessary.
REFER to Cooling System Draining, Filling
and Bleeding - vehicles with 1.8L or 2.0L
Pressure Test engine / Cooling System Draining, Filling and
WARNING: When releasing the system Bleeding - vehicles with 2.5L or 3.0L engine
pressure, cover the coolant expansion in this section.
tank cap with a thick cloth to prevent the 7. Recheck the system by repeating steps 3
possibility of coolant scalding. Failure to and 4 at least twice.
follow this instruction may result in
personal injury. Thermostat Test - Vehicles with 2.5L, 3.0L engine
1. Remove the coolant expansion tank pressure or 2.0L diesel engine
cap.
Remove the thermostat and immerse it in water.
2. Install the special tools to the coolant
Heat the water until it reaches 88º C (190º F). At
expansion tank.
this temperature the thermostat should begin to
3. Pressurize the system to the coolant open. If it does not begin to open, install a new
expansion tank cap release pressure. thermostat. REFER to Thermostat - vehicles with
REFER to Specifications in this section. 2.5L or 3.0L engine in this section.
4. Observe the cooling system pressure tester
gauge reading for approximately two
minutes. The pressure should not drop Radiator Leak Test, Removed From Vehicle
during this time. If the system holds pressure, CAUTION: Radiator internal pressure
proceed to step 7. If the system does not must not exceed 130 kpa (20 psi) or
hold pressure, check it thoroughly for coolant damage may result.
leaks.
5. On vehicles with 2.0L diesel engine - if a Clean the radiator thoroughly before leak testing
coolant leak cannot be found, check the EGR it, to prevent contamination of the water in the
cooler (this may leak internally), engine oil test tank. Leak test the radiator in clean water
cooler (this may produce oil in the coolant with 138 kpa (20 psi) air pressure. Check it
expansion tank and the engine for cylinder thoroughly for air leaks. Install a new radiator if
leakage. REFER to Section 303-00. Drain necessary. REFER to Radiator in this section.
the cooling system, repair any coolant leaks
found and fill and bleed the cooling system
as necessary.
6. All vehicles except with diesel engine - check
the engine for coolant leaks REFER to

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303-03-13 Engine Cooling 303-03-13

DIAGNOSIS AND TESTING (Continued)

Coolant Expansion Tank Pressure Cap Pressure

Test

WARNING: When releasing the system

pressure, cover the coolant expansion
tank cap with a thick cloth to prevent the
possibility of coolant scalding. Failure to
follow this instruction may result in
personal injury.
1. Remove the coolant expansion tank pressure
cap.
2. Use water to clean the area of the rubber
seal and pressure relief valve. Install the
pressure tester and adapter and immerse the
coolant expansion tank pressure cap in water
.
NOTE: If the plunger of the pump is depressed
too quickly, an erroneous pressure reading will
result.
3. Slowly depress the plunger of the pressure
test pump until the pressure test gauge
reading stops increasing, and note the
highest pressure reading obtained.
4. Release pressure by turning the pressure
relief screw counterclockwise. Tighten the
pressure relief screw and repeat step 3 at
least twice to make sure the pressure test
gauge reading is repeatable and within
acceptable gauge reading limits of the
coolant expansion tank pressure cap.
5. If the pressure test gauge readings are not
within the acceptable gauge reading limits,
install a new coolant expansion tank
pressure cap.

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303-03-14 Engine Cooling 303-03-14

GENERAL PROCEDURES

Cooling System Draining, Filling and Bleeding — 1.8L/2.0L (24 122 0)

GENERAL PROCEDURES

5. Install the coolant expansion tank cap.

6. Start the engine, maintain the engine
Draining speed at 2500 RPM for eight minutes or
1. WARNING: When releasing the cooling until the engine reaches normal operating
system pressure, cover the expansion temperature.
tank cap with a thick cloth to prevent 7. Maintain the engine speed at 2500 RPM for
the possibility of scalding. Failure to three minutes after the engine has reached
follow this instruction may result in normal operating temperature.
personal injury. 8. Increase the engine speed to 4000 RPM for
Release the cooling system pressure by five seconds.
slowly turning the coolant expansion tank 9. Decrease the engine speed to 2500 RPM
cap a quarter of a turn. for three minutes.
2. Remove the coolant expansion tank cap. 10. Increase the engine speed to 4000 RPM
3. Raise and support the vehicle. For for five seconds.
additional information, refer to Section 11. Decrease the engine speed to 2500 RPM
100-02. for three minutes.
4. Drain the cooling system. 12. Switch the engine off.
• Allow the coolant to drain into a suitable 13. Check the cooling system for leaks.
container. 14. Allow the engine to cool.
15. Fill the coolant expansion tank to the
MAX mark.

5. Install the radiator drain plug.

6. Lower the vehicle.

Filling and Bleeding

1. Fill the coolant expansion tank to the MAX
mark.
2. NOTE: Do not allow the engine to reach
normal operating temperature.
Start the engine, run the engine briefly at
2500 revolutions per minute (RPM) for 10
seconds to prime the heater circuit.
3. Switch the engine off.
4. Fill the coolant expansion tank 15 mm over
the MAX mark.

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303-03-15 Engine Cooling 303-03-15

GENERAL PROCEDURES

Cooling System Draining, Filling and Bleeding — 2.5L/3.0L (24 122 0)

1. WARNING: When releasing the cooling

system pressure, cover the expansion
tank cap with a thick cloth to prevent
the possibility of scalding. Failure to
follow this instruction may result in
personal injury.
Release the cooling system pressure by
slowly turning the coolant expansion tank
cap a quarter of a turn.
2. Remove the coolant expansion tank cap.
3. Raise and support the vehicle. For
additional information, refer to Section
100-02.
4. Drain the cooling system.
• Allow the coolant to drain into a suitable
container.

5. Install the radiator drain plug.

6. Lower the vehicle.
7. Fill the coolant expansion tank to the MAX
mark.
8. Start the engine and allow it to idle until it
reaches normal operating temperature.
9. Allow the engine to idle for a further five
minutes.
10. Switch the engine off.
11. Allow the engine to cool.
12. Fill the coolant expansion tank to the
MAX mark.
13. Install the coolant expansion tank cap.

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303-03-16 Engine Cooling 303-03-16

REMOVAL AND INSTALLATION

Thermostat Housing — 1.8L/2.0L (24 001 0)

REMOVAL AND INSTALLATION

Removal 5. Disconnect the coolant hose from the

thermostat housing (intake manifold
1. Remove the right-hand headlamp
shown removed for clarity).
assembly. For additional information, refer
to Section 417-01.
2. Drain the cooling system. For additional
information, refer to Cooling System
Draining, Filling and Bleeding in this
section.
3. Detach the power steering pump supply
line bracket.

6. Disconnect the coolant hose from the

thermostat housing (intake manifold
shown removed for clarity).

4. Disconnect the electrical connector from

the thermostat housing (intake manifold
shown removed for clarity).

G37501 en 08/2002 2003.0 Mondeo

303-03-17 Engine Cooling 303-03-17

REMOVAL AND INSTALLATION (Continued)

7. NOTE: The thermostat cannot be removed

from the thermostat housing.
Remove the thermostat housing retaining
bolts and remove the thermostat housing
(intake manifold shown removed for
clarity).
• Discard the O-ring seal.

Installation
1. NOTE: Install a new thermostat housing O-ring
seal.
To install, reverse the removal procedure.

G37501 en 08/2002 2003.0 Mondeo

303-03-18 Engine Cooling 303-03-18

REMOVAL AND INSTALLATION

Thermostat — 2.5L/3.0L (24 454 0)

5. Using the special tool, remove the radiator

Special Tool(s) lower coolant hose from the thermostat
housing.
Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Drain the cooling system. For additional
information, refer to Cooling System
Draining, Filling and Bleeding in this 6. Remove the thermostat housing retaining
section. bolts and separate the thermostat housing.
3. Remove the water pump pulley cover.

7. Remove the thermostat.

4. Using the special tool, disconnect the • Discard the O-ring seal.
coolant hoses and remove the thermostat
housing and the radiator lower coolant
hose.

G37502 en 08/2002 2003.0 Mondeo

303-03-19 Engine Cooling 303-03-19

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Install a new O-ring seal.
To install, reverse the removal procedure.

G37502 en 08/2002 2003.0 Mondeo

303-03-20 Engine Cooling 303-03-20

REMOVAL AND INSTALLATION

Water Pump — 1.8L/2.0L (24 404 0)

Installation
Name Specification
1. To install, reverse the removal procedure.
Merpol grease ESE-M99M144-B
• Install a new O-ring seal and lubricate with
merpol grease.
Removal
1. Drain the cooling system. For additional
information, refer to Cooling System
Draining, Filling and Bleeding in this
section.
2. Loosen the water pump pulley retaining
bolts.

3. Remove the accessory drive belt. For

additional information, refer to Section
303-05.
4. Lower the vehicle.
5. Remove the water pump pulley.
6. Remove the water pump retaining bolts
and remove the water pump (coolant
expansion tank removed for clarity).
• Discard the O-ring seal.

G37504 en 08/2002 2003.0 Mondeo

303-03-21 Engine Cooling 303-03-21

REMOVAL AND INSTALLATION

Water Pump — 2.5L/3.0L (24 404 0)

Removal 6. Disconnect the coolant hose from the wa-

ter pump.
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the air cleaner. For additional
information, refer to Section 303-12.
3. Remove the thermostat housing. For
additional information, refer to Thermostat
- Vehicles with 2 in this section.
4. Remove the water pump drive belt.
• Rotate the water pump drive belt tensioner
clockwise.

7. Disconnect the heater hose and remove

the water pump and coolant hose assem-
bly.

5. Remove the water pump retaining bolts.

8. Remove the coolant hose from the water

pump.

G37505 en 08/2002 2003.0 Mondeo

303-03-22 Engine Cooling 303-03-22

REMOVAL AND INSTALLATION (Continued)

Installation
1. To install, reverse the removal procedure.

G37505 en 08/2002 2003.0 Mondeo

303-03-23 Engine Cooling 303-03-23

REMOVAL AND INSTALLATION

Radiator (24 254 0)

5. Using the special tool, disconnect the ra-
diator upper hose.
Special Tool(s)
Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

Removal
All vehicles
1. Drain the cooling system. For additional
information, refer to Cooling System
Draining, Filling and Bleeding in this 6. Disconnect the coolant expansion tank
section. hose.
2. Remove the cooling fan motor and shroud.
For additional information, refer to Cooling
Fan Motor and Shroud in this section.
3. Using the special tool, disconnect the ra-
diator lower hose.

7. Raise the vehicle

Vehicles with 1.8L or 2.0L engine
8. Using the special tool, disconnect the
coolant expansion tank hose and the ra-
diator upper hose.
Vehicles with 2.5L or diesel engine
4. Lower the vehicle.

G37507 en 08/2002 2003.0 Mondeo

303-03-24 Engine Cooling 303-03-24

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.0L diesel engine All vehicles
9. Disconnect the oil cooler coolant hose 11. NOTE: Support the air conditioning
from the radiator. condenser.
Remove the radiator.
1. Remove the air conditioning condenser
retaining bolts.
2. Slide the cooling fan motor and shroud up-
wards out of the retaining brackets and
downwards to remove the radiator.

10. Detach the oil cooler coolant hose from

the retaining clip and remove the retain-
ing clip from the subframe.

12. Remove the radiator rubber insulators.

Installation
1. To install, reverse the removal procedure.

G37507 en 08/2002 2003.0 Mondeo

303-03-25 Engine Cooling 303-03-25

REMOVAL AND INSTALLATION

Cooling Fan Motor and Shroud — 1.8L/2.0L/2.5L, Vehicles With: Manual

Transaxle/4-Speed Automatic Transaxle/5-Speed Automatic Transaxle (24 222 0)

Removal 5. Using suitable pieces of wire support the

radiator.
All vehicles
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with 2.0L diesel engine
3. Remove the engine undershield.

6. Disconnect the cooling fan motor electrical

connectors and detach the wiring harness
from the radiator support bracket.

All vehicles
4. Remove the splash shield.

Vehicles with 2.5L engine

7. Disconnect the cooling fan motor electrical
connector.

G37508 en 08/2002 2003.0 Mondeo

303-03-26 Engine Cooling 303-03-26

REMOVAL AND INSTALLATION (Continued)

All vehicles
8. Remove the radiator support bracket re-
taining bolts.

9. Remove the cooling fan motor and shroud.

1. Remove the cooling fan motor and shroud
retaining nuts.
2. Slide the cooling fan motor and shroud up-
wards out of the retaining brackets and
then downwards to remove.

Installation
1. To install, reverse the removal procedure.

G37508 en 08/2002 2003.0 Mondeo

303-03-27 Engine Cooling 303-03-27

REMOVAL AND INSTALLATION

Coolant Outlet Connector — 1.8L/2.0L

Removal 4. Disconnect the ignition coil pack electrical

connector.
1. Detach the pipes and hoses from the en-
gine upper cover.

5. Remove the ignition coil pack.

2. Remove the engine upper cover.

6. Drain the cooling system. For additional

information, refer to Section 303-03.
3. Disconnect the spark plug wires from the
ignition coil pack. 7. Disconnect the engine coolant tempera-
ture (ECT) sensor electrical connector.

G37509 en 08/2002 2003.0 Mondeo

303-03-28 Engine Cooling 303-03-28

REMOVAL AND INSTALLATION (Continued)

8. Disconnect the radiator hose and the 11. Remove the coolant outlet connector.
heater hose from the coolant outlet con- • Discard the gasket.
nector.

9. Disconnect the coolant expansion tank

hose from the coolant outlet connector. Installation
1. NOTE: Install a new coolant outlet connector
gasket.
To install, reverse the removal procedure.

10. Disconnect the thermostat housing cool-

ant hose from the coolant outlet connec-
tor.

G37509 en 08/2002 2003.0 Mondeo

303-03-29 Engine Cooling 303-03-29

REMOVAL AND INSTALLATION

Bypass Tube — 2.5L/3.0L

3. Using the special tool, disconnect the
coolant hoses.
Special Tool(s)
Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)

Name Specification
Lubricant
ESE-M99B176-A

Removal 4. Disconnect the engine coolant tempera-

ture (ECT) sensor electrical connector.
Vehicles with 3.0L engine
1. Remove the engine cover.
• Detach the retaining clips.

Vehicles with 3.0L engine

5. Disconnect the positive crankcase ventila-
tion (PCV) hose from the intake manifold
All vehicles and position it to one side.
2. Drain the cooling system. For additional
information, refer to Cooling System
Draining, Filling and Bleeding in this
section.

G188829 en 08/2002 2003.0 Mondeo

303-03-30 Engine Cooling 303-03-30

REMOVAL AND INSTALLATION (Continued)

All vehicles
6. Remove the bypass tube.
• Discard the bypass tube O-ring seal.

Installation
NOTE: Before installing the bypass tube lubricate
the bypass tube O-ring seal.
1. To install, reverse the removal procedure.

G188829 en 08/2002 2003.0 Mondeo

303-04A-1 Fuel Charging and Controls 303-04A-1

SECTION 303-04A Fuel Charging and Controls

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-04-2

DESCRIPTION AND OPERATION

Fuel Charging and Controls............................................................................................... 303-04-3

DIAGNOSIS AND TESTING

Fuel Charging and Controls............................................................................................... 303-04-5

Inspection and Verification ............................................................................................... 303-04-5

REMOVAL AND INSTALLATION

Fuel Injection Supply Manifold ...................................................................... (23 450 0) 303-04-6

Fuel Charging Wiring Harness...................................................................... (36 437 0) 303-04-9
Throttle Body ................................................................................................ (23 198 0) 303-04-11

08/2002 2003.0 Mondeo

303-04A-2 Fuel Charging and Controls — 1.8L/2.0L 303-04A-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Throttle body retaining bolts 10 — 89
Fuel injection supply manifold retaining bolts 25 18 —

G37518 en 08/2002 2003.0 Mondeo

303-04A-3 Fuel Charging and Controls — 1.8L/2.0L 303-04A-3

DESCRIPTION AND OPERATION

Fuel Charging and Controls

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 - Fuel injection supply mani-
1 - Fuel pulse damper fold
2 - Fuel pulse damper snap ring 4 - Fuel injection supply mani-
fold spacer

G37513 en 08/2002 2003.0 Mondeo

303-04A-4 Fuel Charging and Controls — 1.8L/2.0L 303-04A-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
5 - Fuel injector retaining clip
6 - Fuel injector
7 - Fuel injector O-ring seals
8 - Fuel injection supply mani-
fold spacer

G37513 en 08/2002 2003.0 Mondeo

303-04A-5 Fuel Charging and Controls — 1.8L/2.0L 303-04A-5

DIAGNOSIS AND TESTING

Fuel Charging and Controls

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
–Fuel leak(s) – Wiring harness
–Vacuum line – Electrical
–Gasket(s)/seal(s) connector(s)
–Fuel injector(s) – Fuel injector(s)
–Fuel pulse damper
–Throttle body
–Fuel injection supply
manifold
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 WDS to diagnose
the system.

G37514 en 08/2002 2003.0 Mondeo

303-04A-6 Fuel Charging and Controls — 1.8L/2.0L 303-04A-6

REMOVAL AND INSTALLATION

Fuel Injection Supply Manifold (23 450 0)

REMOVAL AND INSTALLATION

4. Remove the engine upper cover.

Name Specification
Engine oil WSS-M2C913-A or
WSS-M2C912-A1

Removal
All vehicles
1. 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
vapors are always present and may 5. Disconnect the fuel injector electrical con-
ignite. Failure to follow these nectors.
instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
Release the fuel system pressure. For
additional information, refer to Section
310-00.
2. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
6. NOTE: Fuel supply line connectors are white
3. Detach the positive crankcase ventilation or are identified by a white band. Fuel return
(PCV) hose and the vacuum hose from the line connectors are red or are identified by a
engine upper cover. red band.
Disconnect the fuel supply line from the
fuel injection supply manifold. For addi-
tional information, refer to Section 310-00.

G37515 en 08/2002 2003.0 Mondeo

303-04A-7 Fuel Charging and Controls — 1.8L/2.0L 303-04A-7

REMOVAL AND INSTALLATION (Continued)

7. Disconnect the vacuum line from the fuel Vehicles built up to 03/2002
pulse damper. 10. Remove the fuel injectors.
1. Remove and discard the fuel injector
retaining clips.
2. Remove the fuel injectors.
• Discard the O-ring seals.

8. Remove the fuel injection supply manifold

retaining bolts and remove the fuel injec-
tion supply manifold.

Vehicles built 03/2002 onwards

11. Detach the fuel injector retaining clips.
1. Release the locking tangs.
2. Remove the fuel injector retaining clips
from the fuel injection supply manifold.

9. Remove the fuel injection supply manifold

spacers.

G37515 en 08/2002 2003.0 Mondeo

303-04A-8 Fuel Charging and Controls — 1.8L/2.0L 303-04A-8

REMOVAL AND INSTALLATION (Continued)

12. Remove the fuel injectors.
• Remove and discard the fuel injector
retaining clips from the fuel injectors.
• Remove and discard the O-ring seals.

Installation
1. 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
vapors are always present and may
ignite. Failure to follow these
instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
NOTE: Install new O-ring seals.
NOTE: Install new fuel injector retaining clips.
To install, reverse the removal procedure.
• Lubricate the fuel injector O-ring seals with
clean engine oil to aid installation.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

G37515 en 08/2002 2003.0 Mondeo

303-04A-9 Fuel Charging and Controls — 1.8L/2.0L 303-04A-9

REMOVAL AND INSTALLATION

Fuel Charging Wiring Harness (36 437 0)

Removal
1. Detach the pipes and hoses from the en- 5. Disconnect the throttle position (TP) sen-
gine upper cover. sor electrical connector.

2. Remove the engine upper cover. 6. Disconnect the camshaft position (CMP)
sensor electrical connector.

3. Disconnect the battery ground cable. For

additional information, refer to Section 7. Disconnect the fuel injector electrical con-
414-01. nectors.
4. Disconnect the idle air control (IAC) valve
electrical connector.

G37516 en 08/2002 2003.0 Mondeo

303-04A-10 Fuel Charging and Controls — 1.8L/2.0L 303-04A-10

REMOVAL AND INSTALLATION (Continued)

8. Disconnect the fuel charging wiring har-
ness electrical connector.

9. Remove the fuel charging wiring harness.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

G37516 en 08/2002 2003.0 Mondeo

303-04A-11 Fuel Charging and Controls — 1.8L/2.0L 303-04A-11

REMOVAL AND INSTALLATION

Throttle Body (23 198 0)

Removal 4. Disconnect the throttle position (TP) sen-

sor electrical connector.
1. Remove the air cleaner outlet pipe.

5. Detach the accelerator cable from the

2. Detach the pipes and hoses from the en-
throttle body.
gine upper cover.

6. Remove the throttle body.

3. Remove the engine upper cover.
• Discard the gasket.

G37517 en 08/2002 2003.0 Mondeo

303-04A-12 Fuel Charging and Controls — 1.8L/2.0L 303-04A-12

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Install a new gasket.
To install, reverse the removal procedure.

G37517 en 08/2002 2003.0 Mondeo

303-04B-1 Fuel Charging and Controls 303-04B-1

SECTION 303-04B Fuel Charging and Controls

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-04-2

DESCRIPTION AND OPERATION

Fuel Charging and Controls............................................................................................... 303-04-3

DIAGNOSIS AND TESTING

Fuel Charging and Controls............................................................................................... 303-04-5

Inspection and Verification ............................................................................................... 303-04-5

REMOVAL AND INSTALLATION

Throttle Body — 2.5L.................................................................................... (23 198 0) 303-04-6

Fuel Injection Supply Manifold — 2.5L.......................................................... (23 450 0) 303-04-8
Fuel Charging Wiring Harness — 2.5L ......................................................... (36 437 0) 303-04-10

08/2002 2003.0 Mondeo

303-04B-2 Fuel Charging and Controls — 2.5L/3.0L 303-04B-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Throttle body retaining bolts 10 — 89
Fuel injection supply manifold retaining bolts 10 — 89

G37524 en 08/2002 2003.0 Mondeo

303-04B-3 Fuel Charging and Controls — 2.5L/3.0L 303-04B-3

DESCRIPTION AND OPERATION

Fuel Charging and Controls

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 - Fuel system pressure re-
1 - Fuel charging wiring harness lease Schrader valve
2 - Fuel injector 4 - Throttle body
5 - Fuel pressure regulator

G37519 en 08/2002 2003.0 Mondeo

303-04B-4 Fuel Charging and Controls — 2.5L/3.0L 303-04B-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
6 - Fuel injection supply mani-
fold

G37519 en 08/2002 2003.0 Mondeo

303-04B-5 Fuel Charging and Controls — 2.5L/3.0L 303-04B-5

DIAGNOSIS AND TESTING

Fuel Charging and Controls

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
–Fuel leak(s) – Wiring harness
–Gasket(s)/seal(s) – Electrical
–Fuel injector(s) connector(s)
–Throttle body – Fuel injector(s)
–Fuel injection supply
manifold
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 WDS to diagnose
the system.

G37520 en 08/2002 2003.0 Mondeo

303-04B-6 Fuel Charging and Controls — 2.5L/3.0L 303-04B-6

REMOVAL AND INSTALLATION

Throttle Body — 2.5L (23 198 0)

REMOVAL AND INSTALLATION

Removal 3. Detach the wiring harness from the throttle

body and disconnect the throttle position
1. Remove the air cleaner outlet tube.
(TP) sensor electrical connector.
1. Disconnect the intake air bypass hose.
2. Disconnect the positive crankcase
ventilation (PCV) hoses.
3. Detach the air cleaner outlet tube retaining
clips.

4. Disconnect the accelerator cable from the

throttle body and remove the accelerator
cable retaining clip.

2. Remove the engine cover.

5. Detach the accelerator cable bracket.

G37523 en 08/2002 2003.0 Mondeo

303-04B-7 Fuel Charging and Controls — 2.5L/3.0L 303-04B-7

REMOVAL AND INSTALLATION (Continued)

6. Remove the throttle body.

• Discard the gasket.

Installation
1. NOTE: Install a new gasket.
To install, reverse the removal procedure.

G37523 en 08/2002 2003.0 Mondeo

303-04B-8 Fuel Charging and Controls — 2.5L/3.0L 303-04B-8

REMOVAL AND INSTALLATION

Fuel Injection Supply Manifold — 2.5L (23 450 0)

3. Release the fuel system pressure. For
additional information, refer to Section
310-00.
Special Tool(s)
4. Remove the upper intake manifold. For
Disconnect Tool, Spring-Lock additional information, refer to Section
Coupling 303-01A / 303-01B.
310-D004 (23-039) 5. Disconnect the fuel injector electrical con-
nectors.

Removal
1. 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
vapors are always present and may
ignite. Failure to follow these
instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at 6. Disconnect the fuel supply line from the
all times and always observe fuel fuel injection supply manifold. For
handling precautions. Failure to follow additional information, refer to Section
these instructions may result in personal 310-00.
injury. 7. Remove the fuel injection supply manifold.
Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the air cleaner outlet pipe.
1. Disconnect the air intake bypass hose.
2. Disconnect the positive crankcase
ventilation (PCV) hoses.
3. Remove the air cleaner outlet pipe retain-
ing clips.

G37521 en 08/2002 2003.0 Mondeo

303-04B-9 Fuel Charging and Controls — 2.5L/3.0L 303-04B-9

REMOVAL AND INSTALLATION (Continued)

8. Remove the fuel injectors from the fuel

injection supply manifold.
• Discard the O-ring seals.

Installation
1. 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
vapors are always present and may
ignite. Failure to follow these
instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
CAUTION: Never use silicone grease to
lubricate the O-ring seals as it will clog
the injectors.
NOTE: Install new O-ring seals.
To install, reverse the removal procedure.
• Lubricate the fuel injector O-ring seals with
clean engine oil to aid installation.
• When installing the fuel injection supply
manifold begin at the front of the engine
and install sequentially working toward the
rear.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

G37521 en 08/2002 2003.0 Mondeo

303-04B-10 Fuel Charging and Controls — 2.5L/3.0L 303-04B-10

REMOVAL AND INSTALLATION

Fuel Charging Wiring Harness — 2.5L (36 437 0)

Removal 4. Detach the fuel charging wiring harness

from the valve cover.
1. Remove the upper intake manifold. For
additional information, refer to Section
303-01A / 303-01B.
2. Disconnect the intake manifold runner
control (IMRC) actuator electrical connec-
tor.

5. Detach and disconnect the fuel charging

wiring harness electrical connectors.

3. Disconnect the engine coolant tempera-

ture (ECT) sensor electrical connector.

6. Disconnect the ignition coil pack and

audio unit capacitor electrical connectors.
• Remove the ground wire from the ignition
coil pack retaining bolt.

G37522 en 08/2002 2003.0 Mondeo

303-04B-11 Fuel Charging and Controls — 2.5L/3.0L 303-04B-11

REMOVAL AND INSTALLATION (Continued)

7. Disconnect the crankshaft position (CKP) 12. Disconnect the fuel injector electrical
sensor and the camshaft position (CMP) connectors.
sensor electrical connectors (Accessory
drive belt shown removed for clarity).

13. Remove the fuel charging wiring harness

(fuel charging wiring harness shown re-
8. Raise and support the vehicle. For moved for clarity).
additional information, refer to Section
100-02.
9. Disconnect the oil pressure switch electri-
cal connector.

Installation
1. NOTE: When installing the fuel injector
10. Lower the vehicle. electrical connectors, begin at the front of the
11. Disconnect the heated oxygen sensor engine, and install sequentially working toward
(HO2S) electrical connector. the rear.
To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

G37522 en 08/2002 2003.0 Mondeo

303-05-1 Accessory Drive 303-05-1

SECTION 303-05 Accessory Drive

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-05-2

DESCRIPTION AND OPERATION

Accessory Drive ................................................................................................................ 303-05-3

Accessory Drive Belt Routing - Vehicles with 1.8L or 2.0L engine .................................... 303-05-3
Accessory Drive Belt Routing - Vehicles with 2.5L engine ................................................ 303-05-3
Accessory Drive Belt Routing - Vehicles with 2.0L diesel engine...................................... 303-05-4
Remote Water Pump Routing - Vehicles with 2.5L engine................................................ 303-05-5
Power Steering Pump Belt Routing - Vehicles with 2.0L diesel engine ............................. 303-05-6

DIAGNOSIS AND TESTING

Accessory Drive ................................................................................................................ 303-05-8

Inspection and Verification ............................................................................................... 303-05-8
Symptom Chart ................................................................................................................ 303-05-11
Component Tests ............................................................................................................. 303-05-12

REMOVAL AND INSTALLATION

Accessory Drive Belt — 1.8L/2.0L ................................................................ (31 413 0) 303-05-14

Accessory Drive Belt — 2.5L/3.0L ................................................................ (31 413 0) 303-05-15

08/2002 2003.0 Mondeo

303-05-2 Accessory Drive 303-05-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Accessory drive belt tensioner retaining bolt - Ve- 25 18 -
hicles with 1.8L or 2.0L engine
Accessory drive belt idler retaining bolt - Vehicles 25 18 -
with 1.8L or 2.0L engine
Accessory drive belt tensioner retaining bolt - Ve- 25 18 -
hicles with 2.5L engine
Accessory drive belt tensioner retaining bolt - Ve- 23 17 -
hicles with 2.0L diesel engine
Accessory drive belt tensioner to generator 55 41 -
bracket retaining bolt - Vehicles with 2.0L diesel
engine
Accessory drive belt idler retaining bolt - Vehicles 48 35 -
with 2.0L diesel engine
Air intake pipe and exhaust gas recirculation 23 17 -
(EGR) tube retaining bolts - Vehicles with 2.0L
diesel engine

G37549 en 08/2002 2003.0 Mondeo

303-05-3 Accessory Drive 303-05-3

DESCRIPTION AND OPERATION

Accessory Drive
DESCRIPTION AND OPERATION

Accessory Drive Belt Routing - Vehicles with

1.8L or 2.0L engine

Item Part Description

Item Part Description Number
Number
6 – Accessory drive belt ten-
1 – Power steering pump pulley sioner pulley
2 – Water pump pulley 7 – Generator pulley
3 – Accessory drive belt 8 – Accessory drive belt idler
4 – Air conditioning (AC) com- pulley
pressor pulley
5 – Crankshaft pulley Accessory Drive Belt Routing - Vehicles with
2.5L engine

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303-05-4 Accessory Drive 303-05-4

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
5 – Accessory drive belt ten-
1 – Power steering pump pulley sioner pulley
2 – Accessory drive belt 6 – Generator pulley
3 – Air conditioning (AC) com-
pressor pulley
Accessory Drive Belt Routing - Vehicles with
4 – Crankshaft pulley
2.0L diesel engine

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303-05-5 Accessory Drive 303-05-5

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
6 – Crankshaft pulley
1 – Accessory drive belt idler
pulley 7 – Generator pulley

2 – Accessory drive belt ten-

sioner pulley
Remote Water Pump Routing - Vehicles with
3 – Accessory drive belt idler 2.5L engine
pulley
4 – Air conditioning (AC) com-
pressor pulley
5 – Accessory drive belt

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303-05-6 Accessory Drive 303-05-6

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
4 – Water pump pulley
1 – Water pump belt tensioner
2 – Camshaft pulley
Power Steering Pump Belt Routing - Vehicles
3 – Water pump drive belt
with 2.0L diesel engine

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303-05-7 Accessory Drive 303-05-7

DESCRIPTION AND OPERATION

Item Part Description

Number
1 – Power steering pump belt
tensioner pulley
2 – Camshaft pulley
3 – Accessory drive belt
4 – Power steering pump pulley

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303-05-8 Accessory Drive 303-05-8

DIAGNOSIS AND TESTING

Accessory Drive
DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical damage.

Visual Inspection Chart

Mechanical
– Damaged or contaminated accessory drive
belt
– Incorrect accessory drive belt
– Accessory drive belt tensioner
– Accessory drive belt idler pulley
– Generator
– Power steering pump
– Air conditioning (A/C) compressor
– Pulley(s)
– Loose hardware
3. If an obvious cause for an observed or
reported concern is found, correct the cause
(if possible) before proceeding to the next
step.
CAUTION: Do not lubricate the accessory
drive belt, accessory drive belt tensioner
or idler pulley(s) as potential damage to 4. The condition of the accessory drive belt
the accessory drive material should be compared against the illustration
construction, accessory drive belt and appropriate action taken.
tensioner damping mechanisam, 1. Small scattered deposits of rubber debris is
accessory drive belt tensioner pulley not a concern and therefore a new
bearing and idler pulley(s) bearing may accessory drive belt should not be
occur. installed.
NOTE: Up to 15 cracks in a accesory drive belt 2. Longer deposits of rubber debris building
rib over a distance of 100 mm may be considered up to 50% of the accessory drive belt rib
acceptable. If the cracks exceed the acceptable height is not a concern but may result in
limit or any chunks are found to be missing, excessive noise. If excessive noise is
install a new accessory drive belt. apparent, install a new accessory drive
belt. REFER to Accessory Drive Belt -
1.8L/2.0L / Accessory Drive Belt -
2.5L/3.0L in this section.
3. Large deposits of rubber debris building up
along the grooves are a concern and may
result in excessive noise and a accessory
drive belt stability concern. If large deposits
or excessive accessory drive belt noise is
apparent, install a new accessory drive
belt. REFER to Accessory Drive Belt -

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303-05-9 Accessory Drive 303-05-9

DIAGNOSIS AND TESTING (Continued)

1.8L/2.0L / Accessory Drive Belt - 6. Check the accessory drive belt for damage. If
2.5L/3.0L in this section. any chunks are found to be missing, install a
new accessory drive belt. REFER to
Accessory Drive Belt - 1.8L/2.0L / Accessory
Drive Belt - 2.5L/3.0L in this section.
7. Check the accessory drive belt for fraying.
The condition of the accessory drive belt
should be compared against the illustrations.
For levels 1 to 3, the accessory drive belt
DOES NOT require changing. For levels 4
and 5 INSTALL a new accessory drive belt.
REFER to Accessory Drive Belt - 1.8L/2.0L /
Accessory Drive Belt - 2.5L/3.0L in this
section.
1. No fraying (new belt)
2. Fraying just starting
5. Check the accessory drive belt for cracks. If 3. Slight fraying
the damage exceeds the acceptable limit, 4. High amount of fraying without cord cuts
install a new accessory drive belt REFER to 5. High amount of fraying with cord cuts
Accessory Drive Belt - 1.8L/2.0L / Accessory
Drive Belt - 2.5L/3.0L in this section.

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303-05-10 Accessory Drive 303-05-10

DIAGNOSIS AND TESTING

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303-05-11 Accessory Drive 303-05-11

DIAGNOSIS AND TESTING

8. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Accessory drive belt noise or • Accessory drive components • CHECK the system with the en-
squeal worn or damaged. gine running and the accessory
drive belt removed (only run the
engine for a very short period). If
a noise is apparent, the cause is
not the accessory drive system.
If a noise is not apparent, the
cause is the accessory drive
system. CHECK where the
noise is coming from and
INSTALL new components as
necessary.
• Accessory drive components • CHECK the accessory drive
incorrectly installed. components are correctly in-
stalled. REPAIR as necessary.
• Accessory drive belt incorrectly • CHECK the accessory drive belt
installed. is correctly installed in the pulley
grooves. INSTALL a new ac-
cessory drive belt as necessary.
REFER to Accessory Drive Belt
- 1.8L/2.0L / Accessory Drive
Belt - 2.5L/3.0L in this section.
• Pulley(s). • CHECK the pulley(s) for dam-
age, freedom of rotation and
alignment. INSTALL new com-
ponents as necessary.
• Lubricant or other contamina- • CHECK the accessory drive belt
tion. for contamination or damage.
REMOVE the accessory drive
belt and wash with detergent
and water. If the accessory drive
belt will not clean or is dam-
aged, INSTALL a new acces-
sory drive belt. REFER to Ac-
cessory Drive Belt - 1.8L/2.0L /
Accessory Drive Belt - 2.5L/3.0L
in this section.
• Accessory drive belt. • CHECK the accessory drive belt
for correct application. INSTALL
a new accessory drive belt.
TEST the system for normal op-
eration. REFER to Accessory
Drive Belt - 1.8L/2.0L / Acces-
sory Drive Belt - 2.5L/3.0L in
this section.

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303-05-12 Accessory Drive 303-05-12

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Accessory drive belt fraying • Accessory drive belt. • CHECK the pulley(s) for dam-
• Pulley(s). age, freedom of rotation and
• Generator. alignment. INSTALL new com-
• Power steering pump. ponents as necessary.
• A/C compressor.
• Accessory drive belt does not • Accessory drive belt cracked or • INSPECT the accesory drive
hold tension damaged. belt for cracks or damage. If the
cracks are within the acceptable
limit, the accessory drive belt is
OK. If the cracks exceed the ac-
ceptable limit, INSTALL a new
accessory drive belt. REFER to
Accessory Drive Belt - 1.8L/2.0L
/ Accessory Drive Belt -
2.5L/3.0L in this section.
• Accessory drive belt tensioner • CHECK the accessory drive belt
worn or damaged. tensioner for correct operation
or damage. INSTALL a new ac-
cessory drive belt tensioner as
necessary.
accessory drive belt tensioner dynamically. If
the accessory drive belt tensioner does not
Component Tests meet the above criteria install a new
accessory drive belt tensioner.
Accessory Drive Belt Tensioner - Static Check
Accessory Drive Belt Tensioner - Dynamic Check
The accessory drive belt tensioner may be
checked statically as follows: The accessory drive belt tensioner may be
checked dynamically as follows:
1. Detach the accessory drive belt in the area of
the accessory drive belt tensioner.
2. Using the correct tool, move the accessory
drive belt tensioner from its relaxed position
through its full stroke and back to the relaxed
position to make sure there is no stick, grab
or bind, and to make sure there is tension on
the accessory drive belt tensioner spring.
3. Rotate the accessory drive belt tensioner
pulley and check for damage, freedom of
rotation and alignment. Install a new
accessory drive belt tensioner as necessary.
4. Inspect the area surrounding the accessory
drive belt tensioner for lubricant or other
contamination. Rectify any leaks before
installing a new accessory drive belt
tensioner. If the accessory drive belt
tensioner is contaminated, do not attempt to
clean it as the damping mechanism inside
may be damaged. Install a new accessory
drive belt tensioner as necessary.
5. If the accessory drive belt tensioner meets
the above criteria proceed to test the

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303-05-13 Accessory Drive 303-05-13

DIAGNOSIS AND TESTING (Continued)

1. With the engine running, observe the

accessory drive belt tensioner movement.
The accessory drive belt tensioner should
move (respond) when the engine is
accelerated rapidly or when the A/C clutch
cycles. If the accessory drive belt tensioner
movement is not constant without engine
acceleration or A/C clutch cycling, a pulley or
shaft is possibly bent, out of round, or the
damping mechanism inside the accessory
drive belt tensioner may be damaged.
Excessive accessory drive belt rideout
(uneven depth of grooves in the accessory
drive belt) may cause excessive accessory
drive belt tensioner movement. Check the
condition by installing a new accessory drive
belt. REFER to Accessory Drive Belt -
1.8L/2.0L / Accessory Drive Belt - 2.5L/3.0L
in this section.

Generator Decoupler - Vehicles with 1.8L or 2.0L

engine with manual transaxle
1. Remove the accessory drive belt. REFER to
Accessory Drive Belt - 1.8L/2.0L in this
section.
2. Using an Allen key to prevent the generator
center shaft from rotating, rotate the
generator decoupler clockwise and
counterclockwise.
3. Make sure the generator decoupler rotates
freely in the counterclockwise direction and is
locked in the clockwise direction. If the
generator decoupler is seized or rotates
freely in both directions, INSTALL a new
generator. REFER to Section 414-02.

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303-05-14 Accessory Drive 303-05-14

REMOVAL AND INSTALLATION

Accessory Drive Belt — 1.8L/2.0L (31 413 0)

REMOVAL AND INSTALLATION

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
3. Remove the splash shield.

4. Remove the accessory drive belt.

1. Rotate the accessory drive belt tensioner
clockwise.
2. Remove the accessory drive belt.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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303-05-15 Accessory Drive 303-05-15

REMOVAL AND INSTALLATION

Accessory Drive Belt — 2.5L/3.0L (31 413 0)

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
3. Remove the splash shield.

4. Remove the accessory drive belt.

1. Rotate the accessory drive belt tensioner
clockwise.
2. Remove the accessory drive belt.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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303-06-1 Starting System 303-06-1

SECTION 303-06 Starting System

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-06-2

DESCRIPTION AND OPERATION

Starting System ................................................................................................................. 303-06-3

DIAGNOSIS AND TESTING

Starting System ................................................................................................................. 303-06-5

Inspection and Verification ............................................................................................... 303-06-5
Symptom Chart ................................................................................................................ 303-06-5
Pinpoint Tests .................................................................................................................. 303-06-6

REMOVAL AND INSTALLATION

Starter Motor — 1.8L/2.0L/2.0L Diesel, Vehicles With: Manual Transaxle/4- (26 204 0)
Speed Automatic Transaxle......................................................................... 303-06-14
Starter Motor — 2.5L .................................................................................... (26 204 0) 303-06-18

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303-06-2 Starting System 303-06-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Starter motor retaining bolts - vehicles with 2.5L or 35 26 -
3.0L engine
Starter motor retaining bolts - vehicles with 1.8L, 25 18 -
2.0L or 2.0L diesel
Starter motor rear support bracket retaining bolt - 35 26 -
vehicles with 1.8L or 2.0L engine
Starter motor rear support bracket retaining nut - 6 - 53
vehicles with 1.8L or 2.0L engine
Starter motor positive cable retaining nut 12 9 -
Ignition switch to starter motor cable retaining nut 6 - 53

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303-06-3 Starting System 303-06-3

DESCRIPTION AND OPERATION

Starting System
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 - Starter motor rear support
1 - Starter motor and starter bracket - Vehicles with 1.8L
motor solenoid or 2.0L engine
2 - Starter motor retaining bolts

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303-06-4 Starting System 303-06-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
4 - Starter motor rear support
bracket retaining nut and
bolt - Vehicles with 1.8L or
2.0L engine
5 - Starter motor solenoid elec-
trical connector retaining
nuts

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303-06-5 Starting System 303-06-5

DIAGNOSIS AND TESTING

Starting System
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 303-06 for Electrical

schematic and connector information.
– Fuse(s)
– Wiring harness
Inspection and Verification – Electrical connector(s)
1. Verify the customer concern. – Relay
2. Visually inspect for obvious signs of electrical – Battery junction box (BJB)
damage. – Switch(es)
– Battery
Visual Inspection Chart – Starter motor
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• The engine does not crank/the • Battery. • REFER to Section 414-00.
relay does click
• Starter motor. • CARRY OUT the starter motor
Component Test using WDS.
• Transmission range sensor - • REFER to WDS.
Vehicles with automatic trans-
axle.
• Relay. • CARRY OUT the relay Compo-
nent Test. REFER to the wiring
diagrams.
• Circuit(s). • GO to Pinpoint Test A.
• The engine does not crank/the • Battery. • REFER to Section 414-00.
relay does not click
• Fuse. • INSTALL a new fuse as re-
quired. If the fuse fails again,
check for short to ground.
• Passive anti-theft system • REFER to Section 419-01B.
(PATS).
• Starter motor. • CARRY OUT the starter motor
Component Test using WDS.
• Ignition switch. • GO to Pinpoint Test B.
• Relay. • CARRY OUT the relay Compo-
nent Test. REFER to the wiring
diagrams.
• Circuit(s). • GO to Pinpoint Test B.

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303-06-6 Starting System 303-06-6

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• The engine cranks slowly • Battery. • REFER to Section 414-00.
• Starter motor. • CARRY OUT the starter motor
Component Test using WDS.
• Circuit(s). • GO to Pinpoint Test C.
• Unusual starter noise • Starter motor. • REMOVE the starter motor.
REFER to Starter Motor -
1.8L/2.0L/2.0L Diesel, Vehicles
With: Manual Transaxle/4-
Speed Automatic Transaxle in
this section. Or REFER to
Starter Motor - 2.5L in this sec-
tion. Or INSPECT the starter
motor gear for damage.
INSTALL a new starter motor as
necessary.
• Flywheel ring gear. • INSPECT the flywheel for dam-
age. REFER to Section 303-00.
• The starter spins but the engine • Starter motor. • REMOVE the starter motor.
does not crank REFER to Starter Motor -
1.8L/2.0L/2.0L Diesel, Vehicles
With: Manual Transaxle/4-
Speed Automatic Transaxle in
this section. Or REFER to
Starter Motor - 2.5L in this sec-
tion. Or INSPECT the starter
motor gear for damage.
INSTALL a new starter motor as
necessary.
• Flywheel ring gear. • INSPECT the flywheel for dam-
age. REFER to Section 303-00.

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE ENGINE DOES NOT CRANK/THE RELAY DOES CLICK
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK VOLTAGE TO STARTER SOLENOID
1 Key in START position.

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303-06-7 Starting System 303-06-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between starter motor
terminal 50, harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A2.
→ No
GO to A3.
A2: CHECK STARTER MOTOR FEED
1 Measure the voltage between starter motor
terminal 30, component side and the battery
positive terminal.

• Is the voltage less than 0.5 volts?

→ Yes
REPAIR circuit 50-BB10 (GY/BK). TEST the
system for normal operation.
→ No
CLEAN and TIGHTEN all battery positive
cable connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new starter motor. REFER to
Starter Motor - 1.8L/2.0L/2.0L Diesel, Vehi-
cles With: Manual Transaxle/4-Speed
Automatic Transaxle in this section. Or
REFER to Starter Motor - 2.5L in this sec-
tion. Or
A3: CHECK CIRCUIT 30-DB1 (RD) FOR OPEN
1 Key in OFF position.
2 Disconnect Starter Relay C910.

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303-06-8 Starting System 303-06-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between starter relay
C910 pin 5, circuit 30-DB1 (RD), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
REPAIR circuit 50-BB10 (GY/BK). TEST the
system for normal operation.
→ No
REPAIR the circuit. CHECK fuse F29 (30A).
INSTALL a new fuse as necessary. If the
fuse fails again for check for a short to
ground. TEST the system for normal opera-
tion.
PINPOINT TEST B: THE ENGINE DOES NOT CRANK/RELAY DOES NOT CLICK
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK SWITCHED POWER TO THE STARTER RELAY
1 Disconnect Starter Relay C910.
2 Key in START position.
3 Measure the voltage between starter motor
relay C910 pin 1, harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to B4.
→ No
GO to B2.
B2: CHECK VOLTAGE AT IGNITION SWITCH CIRCUIT 50-BB12 (GY)
1 Disconnect Ignition Switch C400.

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303-06-9 Starting System 303-06-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Key in START position.
3 Measure the voltage between ignition switch
C400 pin 7, circuit 50-BB12 (GY), component
side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to B3.
→ No
CARRY OUT the Ignition Switch Compo-
nent Test, REFER to the wiring diagrams. If
the concern persists, GO to B7 .
B3: CHECK CIRCUIT 30-BB12 (GY) FOR OPEN
1 Key in OFF position.
2 Measure the resistance between ignition
switch C400 pin 7, circuit 30-BB12 (GY), har-
ness side and starter relay C910 pin 1, circuit
30-BB12 (GY), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to B4.
→ No
REPAIR the circuit. TEST the system for
normal operation.
B4: CHECK CIRCUIT 31S-BB12 (BK/YE) FOR OPEN
NOTE: Make sure that the transaxle is in the PARK position before carrying out this test - (vehicles
with automatic transaxle).
1 Key in OFF position.

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303-06-10 Starting System 303-06-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between starter relay
C910 pin 2, harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new starter relay. TEST the sys-
tem for normal operation.
→ No
For vehicles with manual transaxle, REPAIR
the circuit. TEST the system for normal op-
eration.
For vehicles with automatic transaxle, GO
to B5 .
B5: CHECK CIRCUIT 31S-BB12 (BK/YE) FOR OPEN
1 Disconnect Transmission Range (TR) Sensor
C187.
2 Measure the resistance between transmission
range (TR) sensor C187 pin 9, circuit 31S-
BB12 (BK/YE), and the starter relay C910 pin
2, circuit 30-BB12 (GY/YE), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to B6.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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303-06-11 Starting System 303-06-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B6: CHECK CIRCUIT 31S-BB12A (BK/YE) FOR OPEN
1 Measure the resistance between TR sensor
C187 pin 4, circuit 31S-BB12A (BK/YE), har-
ness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new TR sensor. For vehicles
with 4-speed automatic transaxle, REFER to
Section 307-01A / 307-01B. Or for vehicles
with 5-speed automatic transaxle, TEST the
system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
B7: CHECK FOR POWER TO IGNITION SWITCH
1 Key in OFF position.
2 Measure the voltage between ignition switch
C400 pin 4, circuit 30-BB9 (RD), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
REPAIR circuit 50-BB12 (GY). TEST the
system for normal operation.
→ No
CHECK Fuse F28 (20A). INSTALL a new
fuse as necessary. If the fuse fails again for
check for a short to ground. REPAIR circuit
30-BB9 (RD). TEST the system for normal
operation.

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303-06-12 Starting System 303-06-12

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: THE ENGINE CRANKS SLOWLY
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE VOLTAGE DROP
1 Key in START position.
2 Measure the voltage between starter motor
terminal 30, component side and the battery
positive terminal.

• Is the voltage less than 0.5 volts?

→ Yes
GO to C2.
→ No
CLEAN and TIGHTEN all battery positive
cables connections. TEST the system for
normal operation. If the concern persists,
INSTALL a new battery to starter motor so-
lenoid cable. REFER to Section 414-01.
TEST the system for normal operation.
C2: CHECK FOR GROUND CONNECTION
1 Key in START position.
2 Measure the voltage between starter motor
case and the battery ground cable.

• Is the voltage less than 0.5 volts?

→ Yes
CHECK the battery charging system.
REFER to Section 414-00. TEST the sys-
tem for normal operation.
→ No

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303-06-13 Starting System 303-06-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CLEAN and TIGHTEN all battery negative
cable connections, starter motor mounting
and body to ground straps. TEST the sys-
tem for normal operation. If the concern
persists, INSTALL a new battery negative
cable. TEST the system for normal opera-
tion.

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303-06-14 Starting System 303-06-14

REMOVAL AND INSTALLATION

Starter Motor — 1.8L/2.0L/2.0L Diesel, Vehicles With: Manual Transaxle/4-Speed

REMOVAL AND INSTALLATION

Automatic Transaxle (26 204 0)

Removal Vehicles with 2.0L diesel engine

5. Disconnect the charge air cooler intake
All vehicles
pipe from the air intake pipe.
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with 2.0L diesel engine
3. Remove the engine undershield.

6. Disconnect the air intake hose from the air

intake pipe and exhaust gas recirculation
(EGR) tube.

All vehicles
4. Remove the splash shield.

7. Disconnect the temperature and manifold

absolute pressure (T-MAP) sensor electri-
cal connector.

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303-06-15 Starting System 303-06-15

REMOVAL AND INSTALLATION (Continued)

Vehicles with 1.8L or 2.0L engine

8. Remove the air intake pipe retaining bolts
11. Remove the starter motor rear support
and remove the air intake pipe.
bracket retaining nut and bolt and re-
move the starter motor support bracket.

All vehicles
9. Remove the wiring harness support
All vehicles
bracket retaining nuts and position the
12. Remove the starter motor.
support bracket to one side.
• Discard the gasket.

10. Disconnect the ignition switch and bat-

tery to starter motor solenoid cables.
Installation
Vehicles with 1.8L or 2.0L engine
1. Install the starter motor rear support
bracket to the starter motor and hand
tighten the retaining nut.

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303-06-16 Starting System 303-06-16

REMOVAL AND INSTALLATION (Continued)

2. Make sure the protective cover is correctly 5. Tighten the starter motor rear support
installed into the transmission housing. bracket retaining nut.

All vehicles All vehicles

3. NOTE: Install a new gasket. 6. Connect the ignition switch and battery to
starter motor solenoid cables.
Install the starter motor.

7. Attach the wiring harness support bracket

Vehicles with 1.8L or 2.0L engine and install the support bracket retaining
4. Install the starter motor rear support nuts.
bracket retaining bolt.

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303-06-17 Starting System 303-06-17

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.0L diesel engine 11. Connect the charge air cooler intake pipe
8. Install the air intake pipe and install the air to the air intake pipe.
intake pipe retaining bolts.

All vehicles
9. Connect the T-MAP sensor electrical con- 12. Connect the battery ground cable. For
nector. additional information, refer to Section
414-01.
13. Initialize the door window motors. For
additional information, refer to Section
501-11.

10. Connect the air intake hose to the air in-

take pipe and EGR tube.

G37552 en 08/2002 2003.0 Mondeo

303-06-18 Starting System 303-06-18

REMOVAL AND INSTALLATION

Starter Motor — 2.5L (26 204 0)

Removal 4. Remove the air cleaner.

All vehicles
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the air cleaner outlet pipe.
1. Disconnect the intake air bypass hose.
2. Disconnect the positive crankcase
ventilation (PCV) hoses.
3. Detach the air cleaner outlet pipe retaining
clips.

5. Detach the wiring harness support

bracket.
• Detach the wiring harness retaining clips
from the support bracket.
• Remove the wiring harness support
bracket retaining nuts.

3. Disconnect the Mass Air Flow (MAF) sen-

sor electrical connector.

6. Disconnect the ignition switch and battery

to starter motor solenoid cables.

G37553 en 08/2002 2003.0 Mondeo

303-06-19 Starting System 303-06-19

REMOVAL AND INSTALLATION (Continued)

Installation
Vehicles with manual transaxle
7. Disconnect the reversing lamp switch elec- 1. To install, reverse the removal procedure.
trical connector.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

Vehicles with manual transaxle or 4-speed

automatic transaxle
8. Remove the starter motor retaining bolts
and remove the starter motor.

Vehicles with 5-speed automatic transaxle

9. Remove the starter motor retaining bolts
and remove the starter motor.

G37553 en 08/2002 2003.0 Mondeo

303-07A-1 Engine Ignition 303-07A-1

SECTION 303-07A Engine Ignition

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-07-2

DIAGNOSIS AND TESTING

Engine Ignition................................................................................................................... 303-07-3

Inspection and Verification ............................................................................................... 303-07-3
Symptom Chart ................................................................................................................ 303-07-3

08/2002 2003.0 Mondeo

303-07A-2 Engine Ignition — 1.8L/2.0L 303-07A-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Ignition coil bracket bolts 10 – 89
Ignition coil pack retaining bolts 6 – 53

G37556 en 08/2002 2003.0 Mondeo

303-07A-3 Engine Ignition — 1.8L/2.0L 303-07A-3

DIAGNOSIS AND TESTING

Engine Ignition
DIAGNOSIS AND TESTING

Electrical
• Wiring harness
General Equipment • Electrical connector(s)
• Spark plug(s)
Worldwide Diagnostic System (WDS)
• Spark plug wire(s)
• Ignition coil pack
Inspection and Verification • Powertrain control module (PCM)
3. If an obvious cause for an observed or
1. Verify the customer concern.
reported concern is found, correct the cause
2. Visually inspect for obvious signs of electrical (if possible) before proceeding to the next
damage. step.
4. If the cause is not visually evident, verify the
Visual Inspection Chart symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Engine misfire • Spark plug(s). • CARRY OUT a KV test using
• Spark plug wire(s). WDS.
• Ignition coil pack. • REFER to WDS.
• PCM.
• PCM calibration.
• Engine stumbling • Spark plug(s). • CARRY OUT a KV test using
• Spark plug wire(s). WDS.
• Ignition coil pack. • REFER to WDS.
• PCM.
• PCM calibration.
• Engine lacks power • Spark plug(s). • CARRY OUT a KV test using
• Spark plug wire(s). WDS.
• Ignition coil pack. • REFER to WDS.

G17859 en 08/2002 2003.0 Mondeo

303-07B-1 Engine Ignition 303-07B-1

SECTION 303-07B Engine Ignition

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-07-2

DIAGNOSIS AND TESTING

Engine Ignition................................................................................................................... 303-07-3

Inspection and Verification ............................................................................................... 303-07-3
Symptom Chart ................................................................................................................ 303-07-3

REMOVAL AND INSTALLATION

Ignition Coil Pack — 2.5L ............................................................................. (22 414 0) 303-07-4

08/2002 2003.0 Mondeo

303-07B-2 Engine Ignition — 2.5L/3.0L 303-07B-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Ignition coil bracket 6 — 53

G37558 en 08/2002 2003.0 Mondeo

303-07B-3 Engine Ignition — 2.5L/3.0L 303-07B-3

DIAGNOSIS AND TESTING

Engine Ignition
DIAGNOSIS AND TESTING

Electrical
• Wiring harness
General Equipment • Electrical connector(s)
• Spark plug(s)
Worldwide Diagnostic System (WDS)
• Spark plug wire(s)
• Ignition coil pack
Inspection and Verification • Powertrain control module (PCM)
3. If an obvious cause for an observed or
1. Verify the customer concern.
reported concern is found, correct the cause
2. Visually inspect for obvious signs of electrical (if possible) before proceeding to the next
damage. step.
4. If the cause is not visually evident, verify the
Visual Inspection Chart symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Engine misfire • Spark plug(s). • CARRY OUT a KV test using
• Spark plug wire(s). WDS.
• Ignition coil pack. • REFER to WDS.
• PCM.
• PCM calibration.
• Engine stumbling • Spark plug(s). • CARRY OUT a KV test using
• Spark plug wire(s). WDS.
• Ignition coil pack. • REFER to WDS.
• PCM.
• PCM calibration.
• Engine lacks power • Spark plug(s). • CARRY OUT a KV test using
• Spark plug wire(s). WDS.
• Ignition coil pack. • REFER to WDS.

G17859 en 08/2002 2003.0 Mondeo

303-07B-4 Engine Ignition — 2.5L/3.0L 303-07B-4

REMOVAL AND INSTALLATION

Ignition Coil Pack — 2.5L (22 414 0)

REMOVAL AND INSTALLATION

Removal
1. Disconnect the ignition coil pack electrical Installation
connector.
1. NOTE: Make sure the ground wire is
connected to the ignition coil retaining bolt.
To install, reverse the removal procedure.

2. Disconnect the spark plug wires from the

ignition coil pack.

3. Remove the ignition coil pack.

• Remove the ground wire from the ignition
coil pack retaining bolt.

G37557 en 08/2002 2003.0 Mondeo

303-08-1 Engine Emission Control 303-08-1

SECTION 303-08 Engine Emission Control

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-08-2

DESCRIPTION AND OPERATION

Engine Emission Control ................................................................................................... 303-08-3

DIAGNOSIS AND TESTING

Engine Emission Control ................................................................................................... 303-08-5

Inspection and Verification ............................................................................................... 303-08-5

REMOVAL AND INSTALLATION

Exhaust Gas Recirculation (EGR) Valve....................................................... (23 312 0) 303-08-6

Crankcase Vent Oil Separator ........................................................................................... 303-08-8

08/2002 2003.0 Mondeo

303-08-2 Engine Emission Control — 1.8L/2.0L 303-08-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Exhaust gas recirculation (EGR) valve bolts 25 18 –
EGR valve outlet tube union 55 41 –
Crankcase vent oil separator retaining bolts 10 – 89

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303-08-3 Engine Emission Control — 1.8L/2.0L 303-08-3

DESCRIPTION AND OPERATION

Engine Emission Control

DESCRIPTION AND OPERATION

Item Part Description

Number
1 - Exhaust gas recirculation
(EGR) valve
2 - EGR valve retaining bolts
3 - EGR valve gasket

G37563 en 08/2002 2003.0 Mondeo

303-08-4 Engine Emission Control — 1.8L/2.0L 303-08-4

DESCRIPTION AND OPERATION

Item Part Description

Number
1 - Positive crankcase ventila-
tion (PCV) valve
2 - PCV hose
3 - Crankcase vent oil separator
4 - Crankcase vent oil separator
retaining bolt

G37563 en 08/2002 2003.0 Mondeo

303-08-5 Engine Emission Control — 1.8L/2.0L 303-08-5

DIAGNOSIS AND TESTING

Engine Emission Control

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Vacuum line(s) – Electrical
– Hose(s)/hose joints connector(s)
– Gasket(s) – Wiring harness
– PCV valve – Fuse(s)
– PCV separator – Relay
– EGR valve – EGR valve
– EGR tube
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 WDS to diagnose
the system.

G37564 en 08/2002 2003.0 Mondeo

303-08-6 Engine Emission Control — 1.8L/2.0L 303-08-6

REMOVAL AND INSTALLATION

Exhaust Gas Recirculation (EGR) Valve (23 312 0)

REMOVAL AND INSTALLATION

Removal 5. Remove the air cleaner outlet pipe.

1. Drain the cooling system. For additional
information, refer to Section 303-03.
2. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
3. Detach the pipes and hoses from the en-
gine upper cover.

6. Disconnect the EGR valve electrical con-

nector.

4. Remove the engine upper cover.

7. Disconnect the coolant hose from the EGR

valve.

G37565 en 08/2002 2003.0 Mondeo

303-08-7 Engine Emission Control — 1.8L/2.0L 303-08-7

REMOVAL AND INSTALLATION (Continued)

8. Remove the EGR valve.

• Discard the gasket.

Installation
1. NOTE: Install a new EGR valve gasket.
To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

G37565 en 08/2002 2003.0 Mondeo

303-08-8 Engine Emission Control — 1.8L/2.0L 303-08-8

REMOVAL AND INSTALLATION

Crankcase Vent Oil Separator

Removal 4. Remove the crankcase vent oil separator.

1. Remove the intake manifold. For additional • Discard the gasket.
information, refer to Section 303-01A / 303-
01B.
2. Disconnect the positive crankcase ventila-
tion (PCV) hose from the PCV valve.

Installation
1. NOTE: Install a new crankcase vent oil
3. Remove the PCV valve from the crankcase separator gasket.
vent oil separator. To install, reverse the removal procedure.
1. Push in the locking tangs.
2. Twist the PCV valve to remove.

G37566 en 08/2002 2003.0 Mondeo

303-12-1 Intake Air Distribution and Filtering 303-12-1

SECTION 303-12 Intake Air Distribution and Filtering

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Intake Air Distribution and Filtering .................................................................................... 303-12-2

DIAGNOSIS AND TESTING

Intake Air Distribution and Filtering .................................................................................... 303-12-6

Inspection and Verification ............................................................................................... 303-12-6

REMOVAL AND INSTALLATION

Air Cleaner Intake Pipe — 1.8L/2.0L............................................................. (23 175 0) 303-12-7

Air Cleaner Intake Pipe — 2.5L/2.0L Diesel.................................................. (23 175 0) 303-12-9

08/2002 2003.0 Mondeo

303-12-2 Intake Air Distribution and Filtering 303-12-2

DESCRIPTION AND OPERATION

Intake Air Distribution and Filtering

DESCRIPTION AND OPERATION

Vehicles with 1.8L or 2.0L Engine

Item Part Description

Item Part Description Number
Number
3 - Air cleaner element
1 - Air cleaner outlet pipe
4 - Air cleaner housing
2 - Air cleaner housing cover
5 - Air intake tuning pipe

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303-12-3 Intake Air Distribution and Filtering 303-12-3

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
6 - Air cleaner intake pipe 8 - Air cleaner intake pipe
7 - Intake air resonator box

Vehicles with 2.5L Engine

Item Part Description

Item Part Description Number
Number
2 - Mass air flow (MAF) sensor
1 - Air cleaner outlet pipe

G37572 en 08/2002 2003.0 Mondeo

303-12-4 Intake Air Distribution and Filtering 303-12-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
3 - Air cleaner housing cover 6 - Air intake tuning pipe
4 - Air cleaner element 7 - Air cleaner intake pipe
5 - Air cleaner housing

Vehicles with 2.0L Diesel Engine

G37572 en 08/2002 2003.0 Mondeo

303-12-5 Intake Air Distribution and Filtering 303-12-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
1 - Air cleaner outlet pipe
2 - Mass air flow (MAF) sensor
3 - Air cleaner housing cover
4 - Air cleaner element
5 - Air cleaner housing
6 - Air cleaner intake pipe
blanking cap
7 - Air cleaner intake pipe
8 - Charge air cooler

G37572 en 08/2002 2003.0 Mondeo

303-12-6 Intake Air Distribution and Filtering 303-12-6

DIAGNOSIS AND TESTING

Intake Air Distribution and Filtering

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical damage.

Visual Inspection Chart

Mechanical
– Air leak(s)
– Collapsed pipe(s)
– Air cleaner
– Air cleaner element
– Charge air cooler
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

G37573 en 08/2002 2003.0 Mondeo

303-12-7 Intake Air Distribution and Filtering 303-12-7

REMOVAL AND INSTALLATION

Air Cleaner Intake Pipe — 1.8L/2.0L (23 175 0)

REMOVAL AND INSTALLATION

Removal 4. Remove the left-hand radiator undershield

retaining screws.
1. Disconnect the air cleaner outlet pipe and
the breather hose from the air cleaner
housing.

5. Remove the left-hand front road wheel.

For additional information, refer to Section
204-04.
2. Remove the air cleaner housing.
6. Remove the left-hand front fender splash
shield.

3. Remove the air cleaner intake pipe upper

retaining bolt from the front inner fender.

G37574 en 08/2002 2003.0 Mondeo

303-12-8 Intake Air Distribution and Filtering 303-12-8

REMOVAL AND INSTALLATION (Continued)

7. Remove the upper air cleaner intake pipe. 11. Remove the radiator grille.
• Disconnect the upper air cleaner intake
pipe from the intake air resonator.
• Disconnect the air intake tuning pipe from
the upper air cleaner intake pipe.

12. Remove the lower air cleaner intake pipe.

8. Remove the intake air resonator.

Installation
1. To install, reverse the removal procedure.
9. Detach the fog lamp wiring harness from
the lower air cleaner intake pipe (if
equipped).

10. Lower the vehicle.

G37574 en 08/2002 2003.0 Mondeo

303-12-9 Intake Air Distribution and Filtering 303-12-9

REMOVAL AND INSTALLATION

Air Cleaner Intake Pipe — 2.5L/2.0L Diesel (23 175 0)

Removal 3. Disconnect the clean air hose from the air

cleaner housing.
Vehicles with 2.5L engine
1. Remove the air cleaner outlet pipe.
1. Disconnect the intake air bypass hose.
2. Disconnect the positive crankcase
ventilation (PCV) hoses.
3. Remove the air cleaner outlet pipe retain-
ing clips.

All vehicles
4. Remove the air cleaner housing.

Vehicles with 2.0L diesel engine

2. Detach the air cleaner housing and the air
cleaner outlet pipe.
1. Disconnect the electrical connector.
2. Disconnect the hoses.
3. Lift the air cleaner housing to detach it from
the retaining clips.

5. Remove the air cleaner intake pipe upper

retaining bolt from the front inner fender.

G112888 en 08/2002 2003.0 Mondeo

303-12-10 Intake Air Distribution and Filtering 303-12-10

REMOVAL AND INSTALLATION (Continued)

6. Remove the left-hand radiator undershield 10. Remove the lower air cleaner intake pipe
retaining screws. retaining bolt.

7. Remove the left-hand front road wheel and 11. Remove the upper air cleaner intake pipe.
tyre. For additional information, refer to
Section 204-04.
8. Remove the left-hand front fender splash
shield.

12. Remove the center air cleaner intake

pipe.

9. Remove the center air cleaner intake pipe

retaining bolt.

G112888 en 08/2002 2003.0 Mondeo

303-12-11 Intake Air Distribution and Filtering 303-12-11

REMOVAL AND INSTALLATION (Continued)

13. Detach the fog lamp wiring harness from

the lower air cleaner intake pipe (if
equipped).

14. Lower the vehicle.

15. Remove the radiator grille.

16. Remove the lower air cleaner intake pipe.

Installation
1. To install reverse the removal procedure.

G112888 en 08/2002 2003.0 Mondeo

303-13-1 Evaporative Emissions 303-13-1

SECTION 303-13 Evaporative Emissions

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Evaporative Emissions ...................................................................................................... 303-13-2

DIAGNOSIS AND TESTING

Evaporative Emissions ...................................................................................................... 303-13-4

Inspection and Verification ............................................................................................... 303-13-4

REMOVAL AND INSTALLATION

Evaporative Emission Canister — 4-Door/5-Door ......................................... (29 250 0) 303-13-5

Evaporative Emission Canister — Wagon .................................................... (29 250 0) 303-13-10

08/2002 2003.0 Mondeo

303-13-2 Evaporative Emissions 303-13-2

DESCRIPTION AND OPERATION

Evaporative Emissions
DESCRIPTION AND OPERATION

G37576 en 08/2002 2003.0 Mondeo

303-13-3 Evaporative Emissions 303-13-3

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Item Part Description Number
Number
2 - Evaporative emissions can-
1 - Evaporative emissions can- ister purge valve - Vehicles
ister purge valve - Vehicles with 2.5L engine
with 1.8L or 2.0L engine
3 - Evaporative emissions can-
ister

Evaporative Emissions Canister

Item Part Description

Number
1 - Evaporative emissions can-
ister retaining clip
2 - Evaporative emissions can-
ister
3 - Evaporative emissions can-
ister retaining bolts

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303-13-4 Evaporative Emissions 303-13-4

DIAGNOSIS AND TESTING

Evaporative Emissions
DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Vacuum line(s) – Fuse(s)
– Evaporative – Wiring harness
emission (EVAP) – Electrical connec-
system canister tor(s)
– EVAP system
hose(s)
– EVAP system canis-
ter purge valve
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

G37577 en 08/2002 2003.0 Mondeo

303-13-5 Evaporative Emissions 303-13-5

REMOVAL AND INSTALLATION

Evaporative Emission Canister — 4-Door/5-Door (29 250 0)

REMOVAL AND INSTALLATION

3. Detach the exhaust system from the front

exhaust hanger insulator.
Special Tool(s)
Alignment pins, subframe
205-316 (15-097-A)

General Equipment
Transmission jack

Removal
4. Detach the exhaust system from the mid-
All vehicles dle exhaust hanger insulator.
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Detach the exhaust flexible pipe from the
front muffler pipe.
• Discard the nuts and the gasket.
5. Detach the exhaust system from the
crossmember exhaust hanger insulator (if
equipped).

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303-13-6 Evaporative Emissions 303-13-6

REMOVAL AND INSTALLATION (Continued)

6. Detach the exhaust system from the rear
10. Using a suitable transmission jack,
exhaust hanger insulator and remove the
support the crossmember.
exhaust system.
11. Detach the crossmember (two bolts each
side).

Vehicles with xenon headlamps

7. Remove the rear headlamp levelling
sensor. For additional information, refer to 12. CAUTION: Do not place excessive
Section 417-01. strain on the brake hoses and
All vehicles suspension components.
8. Remove the evaporative emission canister Partially lower the crossmember.
housing retaining bolts.
13. Detach the water separator box cover
from the evaporative emission canister
water separator box.

9. Disconnect the fuel tank vent pipe and the

evaporative emission purge valve pipe
from the evaporative emission canister.

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303-13-7 Evaporative Emissions 303-13-7

REMOVAL AND INSTALLATION (Continued)

14. Detach the evaporative emission canister 1. Install the evaporative emission canister
from the evaporative emission canister into the evaporative emission canister
housing. housing.
1. Lower the evaporative emission canister
into the evaporative emission canister
housing.
2. Push the evaporative emission canister
backwards to lock it into place.

15. Remove the evaporative emission

canister from the evaporative emission
canister housing.
1. Push the evaporative emission canister
forward.
2. Lift the evaporative emission canister up 2. Attach the evaporative emission canister
and remove. to the evaporative emission canister hous-
ing.

Installation
All vehicles
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.

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303-13-8 Evaporative Emissions 303-13-8

REMOVAL AND INSTALLATION (Continued)

3. Attach the water separator box cover to 6. Install the crossmember (two bolts each
the evaporative emission canister water side).
separator box.

7. Connect the fuel tank vent pipe and the

4. WARNING: Do not place excessive evaporative emission canister purge valve
strain on the brake hoses and pipe to the evaporative emission canister.
suspension components.
Raise the crossmember.
5. Using the special tools, align the
crossmember.
1. Insert the alignment pins through the
crossmember alignment holes.
2. Slide the locking plates into the groove and
tighten the alignment pin sleeve.

8. Install the evaporative emission canister

housing retaining bolts.

Vehicles with xenon headlamps

9. Remove the rear headlamp levelling
sensor. For additional information, refer to
Section 417-01.

G37578 en 08/2002 2003.0 Mondeo

303-13-9 Evaporative Emissions 303-13-9

REMOVAL AND INSTALLATION (Continued)

All vehicles 13. Attach the exhaust system to the front

10. Attach the exhaust system to the rear ex- exhaust hanger insulator.
haust hanger insulator.

14. NOTE: Install a new gasket and retaining

11. Attach the exhaust system to the cross- nuts.
member exhaust hanger insulator (if
Attach the exhaust flexible pipe to the
equipped).
front muffler pipe.

12. Attach the exhaust system to the middle

Vehicles with xenon headlamps
exhaust hanger insulator.
15. Initialize the headlamp levelling system
using WDS.

G37578 en 08/2002 2003.0 Mondeo

303-13-10 Evaporative Emissions 303-13-10

REMOVAL AND INSTALLATION

Evaporative Emission Canister — Wagon (29 250 0)

Removal 4. Detach the water separator box cover from

the evaporative emission canister water
WARNING: Do not smoke or carry lighted
separator box.
tobacco or open flame of any type when
working on or near any fuel related
components. Highly flammable vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Disconnect the fuel tank vent pipe and
evaporative emission purge valve pipe
from the evaporative emission canister.

5. Remove the evaporative emission canister

from the evaporative emission canister
housing.
1. Push the evaporative emission canister
forward.
2. Lift the evaporative emission canister up
and remove.

3. Remove the evaporative emission canister

housing retaining bolts.

Installation
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
1. To install, reverse the removal procedure.

G79067 en 08/2002 2003.0 Mondeo

303-14-1 Electronic Engine Controls 303-14-1

SECTION 303-14 Electronic Engine Controls

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 303-14-2

DESCRIPTION AND OPERATION

Electronic Engine Controls ................................................................................................ 303-14-3

Vehicles with 1.8L or 2.0L engine..................................................................................... 303-14-3
Vehicles with 2.5L engine................................................................................................. 303-14-6
Vehicles with 2.0L diesel engine....................................................................................... 303-14-8
Vehicles with 2.0L diesel engine with common rail fuel injection....................................... 303-14-10
Vehicles with manual transaxle ........................................................................................ 303-14-12
Vehicles with automatic transaxle..................................................................................... 303-14-13
All vehicles ....................................................................................................................... 303-14-14

DIAGNOSIS AND TESTING

Electronic Engine Controls ................................................................................................ 303-14-15

Inspection and Verification ............................................................................................... 303-14-15

REMOVAL AND INSTALLATION

Heated Oxygen Sensor (HO2S) LH — 2.5L....................................................................... 303-14-16

Heated Oxygen Sensor (HO2S) RH — 2.5L ...................................................................... 303-14-17
Intake Manifold Runner Control (IMRC) Actuator — 1.8L/2.0L........................................... 303-14-18
Intake Manifold Tuning (IMT) Valve — 1.8L/2.0L............................................................... 303-14-19
Powertrain Control Module (PCM) ................................................................ (29 200 0) 303-14-21

08/2002 2003.0 Mondeo

303-14-2 Electronic Engine Controls 303-14-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Heated oxygen sensor (HO2S) - all except vehi- 48 35 -
cles with diesel engine
Catalyst monitor sensor - all except vehicles with 48 35 -
diesel engine
Intake manifold tuning (IMT) valve retaining bolts - 10 - 89
vehicles with 1.8L or 2.0L engine
Knock sensor (KS) retaining nut - vehicles with 20 15 -
1.8L or 2.0L engine
Camshaft position (CMP) sensor retaining bolt - 6 - 53
vehicles with 1.8L or 2.0L engine
Cylinder head temperature (CHT) sensor retaining 12 9 -
bolt - vehicles with 1.8L or 2.0L engine
Idle air control (IAC) valve retaining bolts - vehicles 10 - 89
with 1.8L or 2.0L engine
Temperature and manifold absolute pressure (T- 3 - 27
MAP) sensor retaining bolt - vehicles with 1.8L or
2.0L engine
Throttle position (TP) sensor retaining bolt - vehi- 1 - 9
cles with 1.8L or 2.0L engine
Powertrain control module (PCM) electrical con- 4 - 35
nector retaining bolt
Crankshaft position (CKP) sensor - vehicles with 7 - 62
diesel engine
Fuel temperature sensor - vehicles with 2.0L die- 15 11 -
sel engine with common rail fuel injection
Exhaust gas recirculation (EGR) tube to EGR 8 - 71
valve retaining bolts - vehicles with 2.0L diesel en-
gine with common rail fuel injection

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303-14-3 Electronic Engine Controls 303-14-3

DESCRIPTION AND OPERATION

Electronic Engine Controls

DESCRIPTION AND OPERATION

Vehicles with 1.8L or 2.0L engine

Item Part Description

Item Part Description Number
Number
2 - Engine coolant temperature
1 - Camshaft position (CMP) (ECT) sensor
sensor

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303-14-4 Electronic Engine Controls 303-14-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
3 - Intake manifold runner con- 6 - Temperature and manifold
trol (IMRC) actuator absolute pressure (T-MAP)
sensor
4 - Idle air control (IAC) valve
5 - Intake manifold tuning valve

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303-14-5 Electronic Engine Controls 303-14-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
1 - Crankshaft position (CKP)
sensor

Item Part Description

Number
1 - Heated oxygen sensor
(HO2S)
2 - Catalyst monitor sensor

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303-14-6 Electronic Engine Controls 303-14-6

DESCRIPTION AND OPERATION

Vehicles with 2.5L engine

Item Part Description

Item Part Description Number
Number
4 - CMP sensor
1 - IAC valve
5 - CKP sensor
2 - ECT sensor
6 - Knock sensor (KS)
3 - Throttle Position (TP) sensor

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303-14-7 Electronic Engine Controls 303-14-7

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
1 - Mass air flow (MAF) sensor

Item Part Description

Item Part Description Number
Number
2 - HO2S RH
1 - HO2S LH
3 - Catalyst monitor sensor

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303-14-8 Electronic Engine Controls 303-14-8

DESCRIPTION AND OPERATION

Vehicles with 2.0L diesel engine

Item Part Description

Item Part Description Number
Number
3 - Fuel injection pump control
1 - Cylinder head temperature unit
(CHT) sensor
2 - CKP sensor

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303-14-9 Electronic Engine Controls 303-14-9

DESCRIPTION AND OPERATION

Item Part Description

Number
1 - T-MAP sensor

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303-14-10 Electronic Engine Controls 303-14-10

DESCRIPTION AND OPERATION

Vehicles with 2.0L diesel engine with common rail fuel injection

Item Part Description

Item Part Description Number
Number
2 - CKP sensor
1 - CHT sensor

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303-14-11 Electronic Engine Controls 303-14-11

DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
1 - MAF sensor
1 - Injector Driver Module (IDM)

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303-14-12 Electronic Engine Controls 303-14-12

DESCRIPTION AND OPERATION

Vehicles with manual transaxle

Item Part Description

Number
1 - Vehicle speed sensor (VSS)

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303-14-13 Electronic Engine Controls 303-14-13

DESCRIPTION AND OPERATION

Vehicles with automatic transaxle

Item Part Description

Item Part Description Number
Number
2 - VSS
1 - Turbine speed sensor (TSS)

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303-14-14 Electronic Engine Controls 303-14-14

DESCRIPTION AND OPERATION

All vehicles

Item Part Description

Number
1 - Powertrain control module
(PCM)

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303-14-15 Electronic Engine Controls 303-14-15

DIAGNOSIS AND TESTING

Electronic Engine Controls

DIAGNOSIS AND TESTING

Electrical
– Fuse(s)
Inspection and Verification
– Wiring harness
1. Verify the customer concern. – Electrical connector(s)
2. Visually inspect for obvious signs of electrical – Relay(s)
damage.
– Sensor(s)
Visual Inspection Chart – Switch(es)
– Powertrain control module (PCM)
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.
Condition Possible Sources Action
• Engine speed will not exceed • Clutch actuation switch. • REFER to WDS.
3000 RPM

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303-14-16 Electronic Engine Controls 303-14-16

REMOVAL AND INSTALLATION

Heated Oxygen Sensor (HO2S) LH — 2.5L

REMOVAL AND INSTALLATION

Removal
1. Remove the engine cover. Installation
CAUTION: When installing a new HO2S, it
is possible that the new component will
be supplied with a longer cable than the
one removed. It is important that the
cable is routed and secured in such a
way that it cannot be damaged by heat or
moving components and will not cause a
noise, vibration or harshness (NVH)
issue.
1. To install, reverse the removal procedure.

2. Disconnect the left-hand HO2S electrical

connector.

3. Raise and support the vehicle. For

additional information, refer to Section
100-02.
4. Remove the left-hand HO2S.

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303-14-17 Electronic Engine Controls 303-14-17

REMOVAL AND INSTALLATION

Heated Oxygen Sensor (HO2S) RH — 2.5L

Removal 1. To install, reverse the removal procedure.

2. Initialize the door window motors. For
1. Disconnect the battery ground cable. For additional information, refer to Section
additional information, refer to Section 501-11.
414-01.
2. Disconnect the right-hand HO2S electrical
connector.

3. Raise and support the vehicle. For

additional information, refer to Section
100-02.
4. Remove the right-hand HO2S.

Installation
CAUTION: When installing a new HO2S, it
is possible that the new component will
be supplied with a longer cable than the
one removed. It is important that the
cable is routed and secured in such a
way that it cannot be damaged by heat or
moving components and will not cause a
noise, vibration or harshness (NVH)
issue.

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303-14-18 Electronic Engine Controls 303-14-18

REMOVAL AND INSTALLATION

Intake Manifold Runner Control (IMRC) Actuator — 1.8L/2.0L

Removal
1. Disconnect the battery ground cable. For 5. Disconnect the vacuum lines from the
additional information, refer to Section IMRC actuator.
414-01.
2. Detach the pipes and hoses from the en-
gine upper cover.

6. Remove the IMRC actuator.

3. Remove the engine upper cover.

Installation

4. Disconnect the IMRC actuator electrical 1. To install, reverse the removal procedure.
connector. 2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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303-14-19 Electronic Engine Controls 303-14-19

REMOVAL AND INSTALLATION

Intake Manifold Tuning (IMT) Valve — 1.8L/2.0L

Removal 5. Disconnect the vacuum line from the IMT

valve.
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Detach the pipes and hoses from the en-
gine upper cover.

6. Disconnect the actuator arm from the IMT

valve.

3. Remove the engine upper cover.

7. Detach the throttle body.

4. Remove the air cleaner outlet pipe.

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303-14-20 Electronic Engine Controls 303-14-20

REMOVAL AND INSTALLATION (Continued)

8. Remove the IMT valve.

Installation
1. To install, reverse the removal procedure.
• Tighten the throttle body retaining bolts in
the sequence shown.

2. Initialize the door window motors. For

additional information, refer to Section
501-11.

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303-14-21 Electronic Engine Controls 303-14-21

REMOVAL AND INSTALLATION

Powertrain Control Module (PCM) (29 200 0)

4. Remove the strut and spring assembly top
mount brace.
General Equipment
Tie straps

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the strut and spring assembly top
mount brace cover.

5. Remove the PCM security shield rivet.

3. Remove the strut and spring assembly top

mount retaining nuts.

6. Detach the engine wiring harness from the

front inner fender.

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303-14-22 Electronic Engine Controls 303-14-22

REMOVAL AND INSTALLATION (Continued)

7. Using suitable tie straps, position the en- 10. Detach the generic electronic module
gine wiring harness to one side. (GEM) from the PCM bracket (right-hand
drive shown).
1. Release the GEM retaining clip and slide
the GEM upwards.
2. Slide the GEM downwards to detach.

8. CAUTION: The PCM electrical

connector ground cable is located
behind the PCM security shield rivet.
Care must be taken when drilling
through the PCM security shield rivet 11. Remove the PCM.
not to drill through the ground cable.
Remove the PCM security shield from the
PCM.

Installation
9. Disconnect the PCM electrical connector. 1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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307-01A-1 Automatic Transmission/Transaxle 307-01A-1

SECTION 307-01A Automatic

Transmission/Transaxle
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 307-01-4

Low-intermediate carrier assembly pinion gear................................................................. 307-01-4
Reverse clutch pack clearance......................................................................................... 307-01-4
Forward/coast clutch pack clearance................................................................................ 307-01-4
Direct clutch pack clearance............................................................................................. 307-01-4
Pump gear end clearance ................................................................................................ 307-01-4
Pump assembly rotating torque ........................................................................................ 307-01-4
Torque converter .............................................................................................................. 307-01-4
Low/reverse clutch pack clearance................................................................................... 307-01-5
Intermediate and overdrive servo ..................................................................................... 307-01-5
Intermediate/overdrive servo apply rod............................................................................. 307-01-5
Reverse/overdrive carrier assembly pinion gear end-play ................................................ 307-01-5
Low-intermediate carrier assembly pinion gear end-play .................................................. 307-01-5
Final drive carrier assembly pinion gear end-play............................................................. 307-01-5
Gear ratios ....................................................................................................................... 307-01-5
Driven sprocket alignment no. 10 thrust washer ............................................................... 307-01-5
Drive sprocket alignment no. 11 shim............................................................................... 307-01-6
Differential end play no. 14 shim ...................................................................................... 307-01-6

DESCRIPTION AND OPERATION

Transaxle Description........................................................................................................ 307-01-8

DIAGNOSIS AND TESTING

Diagnostic Strategy ........................................................................................................... 307-01-36

Preliminary Inspection ....................................................................................................... 307-01-38
Preliminary Inspection ...................................................................................................... 307-01-38
verify customer concern by driving the vehicle.................................................................. 307-01-38
Fluid Level Check............................................................................................................. 307-01-38
High or Low Fluid Level .................................................................................................... 307-01-39
Add Fluid .......................................................................................................................... 307-01-39
Fluid Change - Drain/Refill ............................................................................................... 307-01-39
Fluid Condition Check ...................................................................................................... 307-01-40
Transmission range (TR) sensor ...................................................................................... 307-01-40
Road Test......................................................................................................................... 307-01-41
Check shift linkages for proper adjustment. ...................................................................... 307-01-41
Diagnostics........................................................................................................................ 307-01-42
On-Board Diagnosis with the Diagnostic Tool................................................................... 307-01-42
Preparation....................................................................................................................... 307-01-42
Connecting the Diagnostic Tool........................................................................................ 307-01-42
Perform On-board Diagnosis ............................................................................................ 307-01-44
DIAGNOSTIC TROUBLE CODE CHART ......................................................................... 307-01-45
Special Testing Procedures.............................................................................................. 307-01-47
Static Test ........................................................................................................................ 307-01-48
Test Procedures ............................................................................................................... 307-01-49
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307-01A-2 Automatic Transmission/Transaxle 307-01A-2

Air Pressure Test Results ................................................................................................. 307-01-50

Leakage Inspection........................................................................................................... 307-01-50
External Sealing................................................................................................................ 307-01-51
Fluid Leakage in Torque Converter Area .......................................................................... 307-01-52
Further leakage tests ........................................................................................................ 307-01-53
Leak Check Test With Black Light..................................................................................... 307-01-53
Transmission Fluid Cooler ................................................................................................ 307-01-53
Transmission Fluid Cooler Flow Test ................................................................................ 307-01-53
Diagnosis By Symptom ...................................................................................................... 307-01-56
Diagnosis by Symptom Chart Directions ........................................................................... 307-01-56
Routines ........................................................................................................................... 307-01-57

GENERAL PROCEDURES

Transmission Fluid Cooler - Backflushing and Cleaning..................................................... 307-01-92

Transmission Fluid Drain and Refill .................................................................................... 307-01-93

IN-VEHICLE REPAIR

Fluid Pan, Gasket and Filter............................................................................................... 307-01-94

Main Controls..................................................................................................................... 307-01-97
Turbine Shaft Speed (TSS) Sensor.................................................................................... 307-01-105
Output Shaft Speed (OSS) Sensor..................................................................................... 307-01-106
Halfshaft Seal LH .......................................................................................... (14 303 0) 307-01-107
Halfshaft Seal RH.......................................................................................... (14 304 0) 307-01-115
Transmission Range (TR) Sensor ................................................................. (17 705 0) 307-01-123

REMOVAL AND INSTALLATION

Transaxle ...................................................................................................... (17 214 0) 307-01-125

DISASSEMBLY

Transaxle ...................................................................................................... (17 214 8) 307-01-132

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Chain Sprockets................................................................................................................. 307-01-145

Torque Converter Housing ................................................................................................. 307-01-147
Final Drive Carrier and Differential Assembly ..................................................................... 307-01-150
Forward/Coast/Direct Clutch Cylinder and Reverse Clutch Drum - Assembly .................... 307-01-153
Forward/Coast/Direct Clutches........................................................................................... 307-01-157
Forward One-Way Clutch................................................................................................... 307-01-170
Low/Reverse Piston ........................................................................................................... 307-01-174
Low One-Way Clutch Assembly ......................................................................................... 307-01-175
Main Control Valve Body.................................................................................................... 307-01-177
Transaxle Case.................................................................................................................. 307-01-184
Pump Assembly ................................................................................................................. 307-01-192
Reverse Clutch .................................................................................................................. 307-01-198
Planetary Gearsets and Chain Drive Parts......................................................................... 307-01-202
Torque Converter One-Way Clutch Check ......................................................................... 307-01-205
Torque Converter Cleaning and Inspection ........................................................................ 307-01-206
Torque Converter Flushing................................................................................................. 307-01-207

ASSEMBLY

Transaxle ...................................................................................................... (17 214 8) 307-01-208

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307-01A-3 Automatic Transmission/Transaxle 307-01A-3

INSTALLATION

Transaxle ..................................................................................................... (17 214 0) 307-01-233

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307-01A-4 Automatic Transmission/Transaxle — Vehicles With: 307-01A-4
4-Speed Automatic Transaxle

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Specification
Automatic transmission fluid ESP-M2C166-H
Pipe sealant with Teflon D8AZ-19554-A WSK-M2G350-A2
High-temperature grease ESD-M1C220-A

Capacities
Litres
2.0L engine 7.5
2.0L engine refill capacity (except remaining oil in torque converter) 6.0
2.5L engine 9.6
2.5L engine refill capacity (except remaining oil in torque converter) 6.29

Low-intermediate carrier assembly pinion gear

Description mm
End play 0.15 – 0.72

Reverse clutch pack clearance

Description mm
Clutch plate to retaining ring 0.33 – 0.89
Retaining ring thickness 1.39 – 1.49
Retaining ring thickness 1.53 – 1.63
Retaining ring thickness 1.68 – 1.78

Forward/coast clutch pack clearance

Description mm
Clutch pack clearance 0.23 – 0.96
Retaining ring thickness 1.43 – 1.53
Retaining ring thickness 1.59 – 1.69
Retaining ring thickness 1.75 – 1.85
Retaining ring thickness 1.92 – 2.02

Direct clutch pack clearance

Description mm
Clutch plate to retaining ring 0.52 – 1.12
Retaining ring thickness 1.28 – 1.38
Retaining ring thickness 1.39 – 1.49
Retaining ring thickness 1.52 – 1.62
Retaining ring thickness 1.65 – 1.75

Pump gear end clearance

Description mm
Drive gear clearance 0.04 – 0.08

Pump assembly rotating torque

Description Nm
Drive shaft rotational torque 0.3

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307-01A-5 Automatic Transmission/Transaxle — Vehicles With: 307-01A-5
4-Speed Automatic Transaxle

SPECIFICATIONS (Continued)
Torque converter
Description
Turbine torque check 13.5 Nm
End play check greater than 1.27 mm

Low/reverse clutch pack clearance

Description mm
Clutch plate to retaining ring 0.54 – 1.17
Pressure plate sizes 2.57 – 2.47
Pressure plate sizes 2.36 – 2.26
Pressure plate sizes 2.16 – 2.06

Intermediate and overdrive servo

Description mm
Servo travel (narrow groove) 2.4 – 4.9
Serco travel (wide groove) 2.4 – 4.9

Intermediate/overdrive servo apply rod

Description Number of rings Rod length
F3RP-74188-CB 0 108.1 mm
F3RP-74188-BB 1 107.1 mm
F3RP-74188-AB 2 105.7 mm

Reverse/overdrive carrier assembly pinion gear end-play

Description mm
End play 0.15 – 0.72

Low-intermediate carrier assembly pinion gear end-play

Description mm
End play 0.15 – 0.72

Final drive carrier assembly pinion gear end-play

Description mm
End play 0.17 – 0.65

Gear ratios
Description Ratio
First 2.889:1
Second 1.571:1
Third 1:1
Fourth 0.689:1
Reverse 2.31:1
Final Drive 4.23:1

Driven sprocket alignment no. 10 thrust washer

Description mm
Drive sprocket to converter housing thrust washer (sizes) 1.51 – 1.41
Drive sprocket to converter housing thrust washer (sizes) 1.77 – 1.67
Drive sprocket to converter housing thrust washer (sizes) 2.03 – 1.93

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307-01A-6 Automatic Transmission/Transaxle — Vehicles With: 307-01A-6
4-Speed Automatic Transaxle

SPECIFICATIONS (Continued)
Description mm
Drive sprocket to converter housing thrust washer (sizes) 2.29 – 2.19
Distance measured during gauging procedure and appropriate thrust 1.12 – 0.86
washer:
Distance measured during gauging procedure and appropriate thrust 0.85 – 0.60
washer:
Distance measured during gauging procedure and appropriate thrust 0.59 – 0.34
washer:
Distance measured during gauging procedure and appropriate thrust 0.33 – 0.08
washer:

Drive sprocket alignment no. 11 shim

Description mm
Drive sprocket alignment no. 11 shim Transaxle case to driven sprocket/final 2.20 – 2.10
drive sun gear thrust bearing shim AB (sizes)
Transaxle case to driven sprocket/final drive sun gear thrust bearing shim 2.02 – 1.92
BB (sizes)
Transaxle case to driven sprocket/final drive sun gear thrust bearing shim 1.85 – 1.75
BB (sizes). Transaxle case to driven sprocket/final drive sun gear thrust
bearing shim CB (sizes)
Transaxle case to driven sprocket/final drive sun gear thrust bearing shim 1.67 – 1.57
DB (sizes)
Transaxle case to driven sprocket/final drive sun gear thrust bearing shim 1.50 – 1.40
EB (sizes)
Transaxle case to driven sprocket/final drive sun gear thrust bearing shim 1.32 – 1.22
FB (sizes)
Distance measured during gauging procedure and appropriate thrust bear- 14.34 – 14.17
ing shim AB:
Distance measured during gauging procedure and appropriate thrust bear- 14.16 – 14.00
ing shim BB:
Distance measured during gauging procedure and appropriate thrust bear- 13.99 – 13.83
ing shim CB:
Distance measured during gauging procedure and appropriate thrust bear- 13.82 – 13.66
ing shim DB:
Distance measured during gauging procedure and appropriate thrust bear- 13.65 – 13.49
ing shim EB:
Distance measured during gauging procedure and appropriate thrust bear- 13.48 – 13.32
ing shim FB:

Differential end play no. 14 shim

Description mm
Differential case-to-converter housing thrust bearing shim AA (sizes) 1.08 – 0.98
Differential case-to-converter housing thrust bearing shim BA (sizes) 1.38 – 1.28
Differential case-to-converter housing thrust bearing shim CA (sizes) 1.67 – 1.57
Differential case-to-converter housing thrust bearing shim DA (sizes) 1.97 – 1.86
Differential case-to-converter housing thrust bearing shim FA (sizes) 2.27 – 2.17
Distance measured during gauging procedure and appropriate thrust bear- 130.76 – 130.46
ing shim AA
Distance measured during gauging procedure and appropriate thrust bear- 130.45 – 130.16
ing shim BA
Distance measured during gauging procedure and appropriate thrust bear- 130.15 – 129.87
ing shim CA

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307-01A-7 Automatic Transmission/Transaxle — Vehicles With: 307-01A-7
4-Speed Automatic Transaxle

SPECIFICATIONS (Continued)
Description mm
Distance measured during gauging procedure and appropriate thrust bear- 129.88 – 129.57
ing shim DA
Distance measured during gauging procedure and appropriate thrust bear- 129.56 – 129.27
ing shim FA

Torque Specifications
Description Nm lb-ft lb-in
Drain plug 27 20 -
Main control valve body to transfer plate retaining 12 9 -
bolts
Oil cooler pipe adapter 40 30 -
Differential lubrication tube retaining bolt 13 10 -
Oil filler tube retaining bolt 8 - 71
Line pressure port plug 24 18 -
Manual control lever retaining bolt 27 20 -
Shift cable to control lever bolts 23 17 -
Manual valve detent lever ball stud nut 12 9 -
Parking pawl shaft retaining bolt 8 - 71
Manual control lever shaft 74 55 -
Pressure tap plate bolts 8 - 71
Pump assembly bolts 13 10 -
Pump support bolts 13 10 -
Solenoid valve body bolts 10 - 89
Thermostatic fluid level control valve bolt 12 9 -
Transmission range (TR) sensor retaining bolts 12 9 -
Transaxle case to engine bolts 48 35 -
Turbine shaft speed (TSS) sensor retaining bolt 13 10 –
Vehicle speed sensor (VSS) retaining bolt 5 - 44
Solenoid body to case bolts 10 - 89
Case pressure taps 8 - 71
Transaxle support bracket bolts 48 35 -
Engine rear support insulator bolt 80 59 -
Transaxle oil cooler pipes 23 17 -
Steering knuckle ball joint retaining nut 28 21 -
Power steering gear retaining bolts 50 37 -
Torque converter retaining nuts 36 27 -
Driveshaft stub nut 290 214 -
Torque converter housing to transaxle case 22 16 -
Main control valve cover bolts 20 15 -
Output shaft speed (OSS) sensor retaining bolt 13 10 -

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307-01A-8 Automatic Transmission/Transaxle — Vehicles With: 307-01A-8
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transaxle Description
DESCRIPTION AND OPERATION

The CD4E automatic transaxle is a four-speed, – Planetary gearset

front wheel drive automatic transmission with – Chain drive
electronic controls for:
– Planetary gearset final drive
– Electronic pressure control (EPC) for – Differential pinion and side gears
improved shift quality.
The hydraulic control system of the CD4E has
– Gearshift control
five solenoids that control:
– 3-2 shift timing
– Gearshift pressure (through line pressure
– Coast braking
control).
– Torque converter clutch (TCC)
– Gearshift control (through shift valve position
control).
– Modulated actuation of the torque converter
clutch
– Control of 3-2 shifts
– Engine braking during coast operation

Transaxle Identification Tag

Item Part Description

Number
1 - Model number
View of the automatic transmission
2 - Assembly number
The automatic transmission consists of a four-
part torque converter with lock-up clutch as well 3 - Serial number (contains the
as the following components: build date)
4 - Part number
5 - Bar code

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307-01A-9 Automatic Transmission/Transaxle — Vehicles With: 307-01A-9
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Final drive, chain drive, differential

Item Part Description

Item Part Description Number
Number
14 - Final drive planet gear
1 - Final drive ring gear spacer (4 req'd)
2 - Final drive ring gear snap- 15 - Final drive planet gear nee-
ring dle bearing (4 req'd)
3 - Differential carrier bearing, 16 - Final drive planet gear (4
no. 15 req'd)
4 - Thrust washer, no.14 (selec- 17 - Final drive pinion shaft
tive fit)
18 - Final drive planetary gearset
5 - Speedometer drive gear and carrier
6 - Differential housing 19 - Final drive pinion shaft snap-
7 - Thrust washer ring

8 - Differential pinion gear 20 - Cover - drive chain

9 - Thrust washer 21 - Drive chain

10 - Differential side gear 22 - Drive chain sprocket thrust

bearing, no. 13
11 - Differential pinion shaft
23 - Drive chain sprocket
12 - Roll pin
24 - Cover - rear drive chain
13 - Final drive planet gear thrust
washer (8 req'd) 25 - Magnet

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307-01A-10 Automatic Transmission/Transaxle — Vehicles With: 307-01A-10

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
26 - Cover - rear drive chain 28 - Shim - drive chain sprocket,
no. 11 (selective fit)
27 - Drive chain sprocket bear-
ing, no.12 29 - Drive chain sprocket bear-
ing, no.18

Torque converter, converter housing, clutches

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307-01A-11 Automatic Transmission/Transaxle — Vehicles With: 307-01A-11
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
1 - Torque converter 27 - Low/reverse clutch return
spring snap-ring
2 - Torque converter hub seal
28 - Low/reverse clutch return
3 - Stator support
spring assembly
4 - Fluid level indicator
29 - Low/reverse clutch piston
5 - Fluid filler tube outer seal (large)
6 - Fluid filler tube grommet 30 - Low/reverse clutch piston
7 - Differential line 31 - Inner seal - lower/reverse
clutch piston (small)
8 - Torque converter housing
32 - Reverse/overdrive sun gear
9 - Pipe plug, 1/8-27 dry seal and housing
10 - Fluid line connector 33 - Reverse/overdrive sun gear
11 - Transaxle flange gasket thrust bearing, no. 7
12 - Drive sprocket thrust 34 - Low-intermediate ring gear
washer, no.10 (selective fit) assembly
13 - Stator support bearing, 35 - Low-intermediate carrier
no.17 thrust bearing, no. 6
14 - Reverse/overdrive ring gear 36 - Low-intermediate carrier
assembly 37 - Low-intermediate sun gear
15 - Drive sprocket bearing, thrust bearing, no. 5
no.16 38 - Forward one-way clutch
16 - Reverse/overdrive ring gear 39 - Forward one-way clutch and
thrust bearing sun gear assembly
17 - Low one-way clutch 40 - Low-intermediate sun gear
18 - Reverse/overdrive carrier assembly
assembly (with captured no. 41 - Snap-ring (2 req'd)
8 thrust bearing)
42 - Forward one-way clutch
19 - One-way clutch snap-ring snap-ring
20 - One-way clutch thrust 43 - Forward one-way clutch
washer outer race
21 - One-way clutch assembly 44 - Forward one-way clutch
22 - Low/reverse clutch (sprag)
23 - Low/reverse wave spring 45 - Coast clutch hub
24 - Low/reverse clutch pressure 46 - Turbine shaft thrust bearing,
plate no.4
25 - Low/reverse clutch internal 47 - Coast clutch hub snap-ring
spline clutch plates (friction 48 - Turbine shaft
plates) (3 req'd)
49 - Forward/coast/direct clutch
26 - Low/reverse clutch external cylinder hub seal
spline clutch plates (steel) (3
req'd) 50 - Forward/direct clutch pres-
sure plate snap-ring

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307-01A-12 Automatic Transmission/Transaxle — Vehicles With: 307-01A-12

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
51 - Forward clutch 61 - Coast clutch piston and seal
assembly
52 - Forward clutch pressure
plate 62 - Forward clutch piston outer
seal
53 - Forward clutch external
spline clutch plates (steel)(2 63 - Forward clutch piston as-
req'd) sembly
54 - Forward clutch internal 64 - Forward clutch piston inner
spline clutch plates (fric- seal
tion)(3 req'd)
65 - Forward/coast/direct clutch
55 - Coast clutch pressure plate cylinder assembly
56 - Coast clutch internal spline 66 - Direct clutch piston outer
clutch plates (friction)(2 seal
req'd)
67 - Direct clutch piston assem-
57 - Coast clutch external spline bly
clutch plates (steel)(2 req'd)
68 - Direct clutch piston inner
58 - Coast clutch seal
59 - Forward clutch spring snap- 69 - Direct clutch return spring
ring
70 - Direct clutch spring snap-
60 - Forward/coast clutch return ring
spring

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307-01A-13 Automatic Transmission/Transaxle — Vehicles With: 307-01A-13
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Oil pump, sensors, clutches

Item Part Description

Item Part Description Number
Number
5 - Pump support assembly
1 - Intermediate and overdrive
band assembly 6 - Pump body separator plate
gasket
2 - Pump assembly
7 - Pump body separator plate
3 - Pump support seal ring
8 - Pump drive gear insert
4 - Pump support seal ring (6
req`d) 9 - Pump drive gear

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307-01A-14 Automatic Transmission/Transaxle — Vehicles With: 307-01A-14

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
10 - Pump driven gear 30 - Drum - reverse clutch
11 - Pump seal 31 - Piston - reverse clutch
12 - Pump body 32 - Return spring - reverse
clutch
13 - Turbine shaft speed sensor
(TSS sensor) 33 - Snap-ring
14 - Seal - TSS sensor 34 - External spline clutch plates
(steel) - reverse clutch (2
15 - Transaxle identification tag
req'd)
16 - Fluid pipe connector
35 - Internal spline clutch plates
17 - Differential seal (2 req'd) (friction plates) - reverse
clutch (2 req'd)
18 - Transaxle drain plug
36 - Pressure plate - reverse
19 - Line pressure port plug clutch
20 - Transaxle case 37 - Snap-ring - reverse clutch
21 - Direct clutch pressure plate (selective fit)
22 - Reverse clutch cylinder 38 - Hub - reverse clutch
seals (2 req'd) 39 - Snap-ring - reverse clutch
23 - Direct clutch thrust washer, hub
no.2 40 - Pump support thrust bear-
24 - Direct clutch external spline ing, no. 1
clutch plates (steel)(3 req'd) 41 - Pump drive shaft
25 - Direct clutch internal spline 42 - Intermediate/overdrive servo
clutch plates (friction)(3 return spring
req'd)
43 - Intermediate/overdrive servo
26 - Direct clutch pressure plate piston and rod assembly
27 - Direct clutch pressure plate 44 - Intermediate/overdrive servo
snap-ring cover
28 - Direct clutch shell 45 - Intermediate/overdrive servo
29 - Reverse clutch cover snap-ring

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307-01A-15 Automatic Transmission/Transaxle — Vehicles With: 307-01A-15
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Selector lever, TR switch

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307-01A-16 Automatic Transmission/Transaxle — Vehicles With: 307-01A-16

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
1 - Manual control lever 9 - Seal - manual control lever
shaft
2 - Manual control lever seal
10 - Parking pawl shaft
3 - Manual valve actuator rod (Z
link) 11 - Parking pawl return spring
4 - Manual valve detent lever 12 - Parking pawl
5 - Manual valve detent lever 13 - Retainer and bolt - parking
shaft pawl shaft
6 - Shaft retaining pin (2 req'd) 14 - Parking pawl ratchet spring
7 - Manual valve detent lever 15 - Manual control lever assem-
actuating rod bly
8 - Transmission range switch

Main control valve body assembly

Item Part Description

Item Part Description Number
Number
4 - Vent - main control cover
1 - Main control cover
5 - Seal - final drive oil line
2 - Gasket - main control cover
6 - Final drive oil line
3 - Grommet - main control
cover vent

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307-01A-17 Automatic Transmission/Transaxle — Vehicles With: 307-01A-17
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
7 - Main control valve body as- 18 - Manual valve detent spring
sembly
19 - Main control valve body
8 - Solenoid valve body (trans-
20 - Solenoid housing separator
axle control)
plate gasket (2 req'd)
9 - Solenoid valve body retain-
21 - Solenoid housing separator
ing clip
plate
10 - Solenoid valve body gasket
22 - Transfer plate
11 - Pressure tap plate
23 - Fluid level control valve
12 - Pressure tap plate gasket
24 - Fluid level control valve
13 - Servo body assembly bracket
14 - Intermediate and overdrive 25 - Transaxle case
servo valve plug
26 - Filter and seal
15 - Intermediate and overdrive
27 - Filter recirculating regulator
servo plug seal
exhaust seal
16 - Servo body separator gas-
28 - Transaxle identification tag
kets (2 req'd)
17 - Servo body separator plate

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307-01A-18 Automatic Transmission/Transaxle — Vehicles With: 307-01A-18
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Thrust bearings, thrust washers

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307-01A-19 Automatic Transmission/Transaxle — Vehicles With: 307-01A-19
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
1 - Low-intermediate planet 13 - Driven sprocket thrust
washer washer, no. 13
2 - Thrust bearing no. 9 - re- 14 - Driven sprocket bearing, no.
verse/overdrive ring gear 12
3 - Thrust bearing no. 8 - re- 15 - Driven sprocket bearing, no.
verse/overdrive planet car- 18
rier
16 - Shim no. 11 - driven
4 - Drive sprocket thrust sprocket
washer, no. 10
17 - Bearing no. 16 - re-
5 - Converter stator bearing verse/overdrive ring gear
6 - Stator support bearing, 18 - Direct clutch thrust washer,
no.17 no. 2
7 - Thrust washer - differential 19 - Pump support thrust bear-
side gear ing, no.1
8 - Bearing no. 15 - differential 20 - Thrust bearing no. 4 - tur-
pinion gear bine shaft
9 - Shim no. 14 - differential pin- 21 - Low-intermediate sun gear
ion gear bearing thrust bearing, no.5
10 - Thrust washer 22 - Low-intermediate planet car-
rier thrust bearing, no.6
11 - Final drive planet gear nee-
dle bearing 23 - Thrust bearing no. 7 - re-
verse/overdrive sun gear
12 - Final drive planet gear thrust
washer 24 - Planet gear washer
25 - Planet gear needle bearing

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307-01A-20 Automatic Transmission/Transaxle — Vehicles With: 307-01A-20
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Bushes

Item Part Description

Item Part Description Number
Number
5 - Case bush
1 - Low-intermediate sun gear
bush 6 - Rear bush - final drive differ-
ential pinion gear
2 - Bush - reverse/overdrive hub
plate 7 - Front bush - final drive dif-
ferential pinion gear
3 - Converter impeller hub bush
8 - Final drive sun gear bush
4 - Stator support bush

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307-01A-21 Automatic Transmission/Transaxle — Vehicles With: 307-01A-21
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description selector. Engine braking is available in second
Number and third gear if the transmission control switch is
switched on (O/D deactivated, TCIL display on).
9 - Bush - reverse/overdrive
drum gear (2) "2"

10 - Low-intermediate gear hub In position "2", second gear remains engaged if

bush the transmission is shifted manually or
automatically up or down. If position "2" is
11 - Turbine shaft bush selected while the vehicle is stationary, the
vehicle will pull away in second gear to provide
12 - Direct clutch bush
maximum traction on slippery surfaces. In
13 - Pump assembly drive bush position "2" engine braking is available in second
gear.
14 - Bush - reverse clutch drum
support (1) "1"
15 - Forward/direct clutch cylin- In position "1", first gear remains engaged if the
der bush transmission is downshifted manually or
automatically. The transaxle is prevented from
16 - Bush - reverse clutch drum down shifting into first gear above a specific
speed - approximately 48 km/h (30 mph) - to
Transaxle Range Selection
protect the powertrain from over-speeding.
The selector lever has six settings: P, R, N, D, 2, Engine braking is also available in position "1",
1. A transmission control switch allows the driver which can be particularly useful on steep
to prevent a shift into fourth gear (overdrive). The descents.
engine braking effect can be used in second and
Transaxle Shift Patterns
third gear.
Upshifts
(P) Park
The powertrain control module (PCM) controls
In the PARK position, no powerflow is transferred
transmission upshifts. The PCM receives signals
through the transaxle. A shift lever connected to
from various sensors and inputs from the driver
a set of cams presses the parking pawl into the
which it uses to control gearshifts, gearshift
park gear on the driven sprocket. This locks the
pressure and actuation of the lock-up clutch
final drive and prevents the vehicle from rolling.
For safety reasons, always apply the parking Downshifts
brake whenever the vehicle is parked.
Under certain conditions the transaxle will
(R) Reverse downshift automatically to a lower gear range
(without moving the transaxle range selector
REVERSE allows the vehicle to be operated in a
lever). There are three categories of automatic
rearward direction, at a reduced gear ratio.
downshifts: coastdown, torque demand, and
Engine braking is provided in REVERSE.
forced or kickdown shifts.
(N) Neutral
Coastdown
As in PARK, there is no power transferred
The coastdown downshift occurs when the
through the transaxle in NEUTRAL. However, the
vehicle is coasting down to a halt.
final drive is not locked by the parking pawl, so
the wheels are free to rotate. The vehicle may be Torque Demand
started in NEUTRAL.
The torque demand downshift occurs
(D) Drive automatically during part throttle acceleration
when the demand for torque is greater than the
The DRIVE position provides all automatic shifts
engine can provide at that gear ratio. The
(first through fourth), the engagement and
engaged torque converter clutch will be
disengagement of the torque converter clutch
disengaged to provide additional acceleration, if
and optimum fuel economy during normal
required.
operation. Engine braking is provided in the
fourth gear. Fourth gear (overdrive) may be Kickdown
disabled by actuating the transmission control
switch located on the transmission range

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307-01A-22 Automatic Transmission/Transaxle — Vehicles With: 307-01A-22

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Maximum acceleration is achieved when the Overdrive (O/D) may be cancelled by actuating
driver forces a downshift by flooring the the transmission control switch in the transaxle
accelerator pedal. Forced kickdown into second range selector lever. The system automatically
gear is only possible below 88 km/h. At speeds engages the O/D mode if the ignition switch is
less than 40 km/h kickdown causes the turned to RUN. O/D mode is disabled if the
transmission to downshift into first gear. These transmission control switch is operated with the
specifications are subject to modification due to ignition switch turned to RUN. Pressing the
changes in tire size and engine settings. transmission control switch again reverts to the
O/D mode. The transmission control indicator
Transmission Control Switch and Lamp
lamp switches alternately on and off when the
Operation
transmission control switch is cycled.

Torque Converter Main Components and Functions - 235mm (9.25 inch)

Item Part Description

Item Part Description Number
Number
5 - Turbine
1 - Shaft pump drive
6 - Stator
2 - Shaft assembly, turbine
7 - Thrust bearing
3 - Cover
8 - Impeller
4 - Plate, torque converter lock-
up clutch

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307-01A-23 Automatic Transmission/Transaxle — Vehicles With: 307-01A-23
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Torque Converter Main Components and Functions - 261mm (10.25 inch)

The impeller and cover assembly drives the

Item Part Description impeller blades and pump assembly. The
Number impeller is primarily responsible for driving the
1 - Shaft pump drive turbine with hydraulic fluid by means of
centrifugal force. The cover provides a mating
2 - Shaft assembly, turbine surface for the torque converter clutch piston
3 - Cover plate and damper.

4 - Plate, torque converter lock- Turbine

up clutch The impeller drives the turbine with hydraulic fluid
5 - Turbine by means of centrifugal force. The turbine
transmits the input torque via the turbine shaft to
6 - Stator the drive chain and the driven sprocket.
7 - Thrust bearing Stator
8 - Impeller The stator directs the flow of fluid back from the
turbine to the impeller so that the fluid rotates in
The CD4E torque converter is a four-element the same direction as the impeller. This process
assembly. The torque converter contains an also serves to multiply torque.
impeller, a turbine, a stator and a torque
converter lock-up clutch to reduce fuel Torque Converter Clutch (TCC)
consumption. It couples the engine to the turbine The torque converter clutch (TCC) provides a
shaft assembly, provides torque multiplication mechanical link or direct drive between the
and absorbs engine shock of gear shifting. engine crankshaft and the turbine shaft when it is
Impeller and Cover engaged. The application of the torque converter
clutch is controlled by the powertrain control
module (PCM). Under certain conditions the PCM

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307-01A-24 Automatic Transmission/Transaxle — Vehicles With: 307-01A-24

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

sends the corresponding signal to the TCC Item Part Description
solenoid valve. As a result, the pressure of the Number
fluid in the torque converter forces the piston
plate and damper against the cover and creates 1 - Low-intermediate sun gear
a mechanical link between the engine and the assembly
transmission. 2 - Low-intermediate planet car-
Geartrain rier
The geartrain includes the planetary gearsets, 3 - Low-intermediate ring gear
the actuating components and the final drive assembly
gearset and differential.
4 - Reverse/overdrive sun gear
Planetary Gearsets and shell assembly
The CD4E transmission has two planetary 5 - Reverse/overdrive planet
gearsets for reverse drive and the four forward carrier assembly
gears. The planetary gearsets consist of the
following components: 6 - Reverse/overdrive ring gear
assembly
– Low-intermediate sun gear assembly
7 - Splined together
– Low-intermediate planet carrier
– Low-intermediate ring gear assembly 8 - Splined together
– Reverse/overdrive sun gear and shell Turbine Shaft
assembly
The turbine shaft connects the torque converter
– Reverse/overdrive planet carrier assembly
stator with the forward/coast/direct clutch
– Reverse/overdrive ring gear assembly cylinder. When engaged, the forward/coast/direct
clutch cylinder transmits the input torque to the
Planetary Gearsets reverse/overdrive ring gear, which also acts as a
drive sprocket. This allows input torque to be
transmitted from the torque converter to the drive
chain and driven sprocket.

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307-01A-25 Automatic Transmission/Transaxle — Vehicles With: 307-01A-25
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Drive chain Item Part Description
Number
2 - Drive chain
3 - Driven sprocket assembly
(with park gear and final
drive sun gear)

Drive Chain and Sprockets

A drive chain transfers the torque from the
turbine to the planetary gearsets. The drive chain
consists of the following components:
– Reverse/overdrive ring gear assembly which
also acts as a drive sprocket,
– Driven sprocket
– Drive chain
The drive chain connects the reverse/overdrive
sun gear with the driven sprocket. The final drive
sun gear located on top of the driven sprocket
meshes with the final drive gearset.

Item Part Description

Number
1 - Drive sprocket (with re-
verse/overdrive ring gear)

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307-01A-26 Automatic Transmission/Transaxle — Vehicles With: 307-01A-26
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Final Drive Gearset

Item Part Description

Item Part Description Number
Number
14 - Shim for differential planet
1 - Differential ring gear gear
2 - Snap-ring, differential ring 15 - Bearing for differential planet
gear gear
3 - Differential bearing (no. 15) 16 - Differential planet gear
4 - Shim for differential bearing 17 - Planet gear shaft
(no. 14)
18 - Differential
5 - Speedometer drive gear
19 - Snap-ring
6 - Differential gear case
20 - Lower chain cover
7 - Pinion thrust washer
21 - Drive chain
8 - Pinion gear
22 - Thrust bearing, driven
9 - Thrust washer for differential sprocket (no. 13)
side gear
23 - Driven sprocket
10 - Differential side gear
24 - Upper chain cover
11 - Differential pinion shaft
25 - Magnet
12 - Pinion shaft roll pin
26 - Complete upper chain cover
13 - Thrust washer of differential
planet gear

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307-01A-27 Automatic Transmission/Transaxle — Vehicles With: 307-01A-27
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
27 - Driven sprocket bearing, 1 - Differential case (with final
no.12 drive carrier)
28 - Shim (no .11) for driven 2 - Differential pinion shaft
sprocket
3 - Differential side gear
29 - Driven sprocket bearing,
4 - Differential pinion gear
no.18
The differential assembly drives the differential
The final drive consists of a planetary gearset
pinion gears and the differential side gears which
that transfers and multiplies torque from the
in turn drive the front wheel driveshaft and joints.
planetary gearsets to the differential. The final
It provides differential action if the driving wheels
drive consists of the following components:
are turning at different speeds. The differential
– Final drive sun gear: is chain driven by the assembly consists of the following components:
reverse/overdrive ring gear assembly and
– Differential case (part of the final drive carrier)
transfers torque to the final drive carrier.
– Two pinion gears supported by a pinion shaft
– Final drive carrier: the final drive carrier acts
as the driven member and is part of the – Two side gears supported by the differential
differential case. case and halfshafts
– Final drive ring gear: is located in the Apply Components:
converter housing and is always the held Band - intermediate and overdrive
member of the final drive planetary gearset.
The intermediate and overdrive brake band
assembly holds the reverse clutch drum
Differential Assembly assembly to the transaxle case in second and
fourth gear. This action causes the
reverse/overdrive sun gear and shell assembly to
be held stationary in second and fourth gears.
Intermediate and Overdrive Servo
The intermediate and overdrive servo is the
hydraulic actuator for the intermediate and
overdrive band assembly. Line pressure is
applied through the servo apply circuit where it
works on one side of the servo piston. This forces
the piston to move up the servo bore in the
transaxle case, which moves the servo apply rod
against one side of the intermediate and
overdrive band assembly. Because the other side
of the intermediate and overdrive band assembly
is anchored to the transaxle case, the sides of
the intermediate and overdrive band assembly
are squeezed around the reverse clutch drum
assembly, holding the reverse clutch drum
assembly stationary.
Clutch - Forward
The forward clutch connects the turbine shaft to
the outer race of the forward one-way clutch
which in turn drives the low/intermediate sun gear
in all forward gear ranges. However, in fourth
gear, the forward clutch transmits no power
because the forward one-way clutch is
overrunning. The forward clutch is a multi-disc

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307-01A-28 Automatic Transmission/Transaxle — Vehicles With: 307-01A-28

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

clutch and is contained in the forward/coast/direct The hydraulic system uses transmission fluid to
clutch cylinder assembly. cool, to lubricate, and to provide hydraulic
pressure to the hydraulic circuits within the
Clutch - Direct
transaxle.
The direct clutch connects the turbine shaft to the
low/intermediate ring gear assembly when the
vehicle is in third and fourth gears. It is a multi- Pump Assembly
disc clutch and is contained in the
forward/coast/direct clutch cylinder assembly.
Clutch - Reverse
The reverse clutch connects the turbine shaft to
the reverse/overdrive sun gear and shell
assembly when the vehicle is in reverse gear. It
is a multi-disc clutch and is contained in the
reverse clutch drum assembly.
Clutch - Coast
The coast clutch is a multi-disc clutch located
beneath the forward clutch in the
forward/coast/direct clutch cylinder assembly. It
connects the low/intermediate sun gear assembly
to the turbine shaft assembly when the
transmission control switch is on and in the
DRIVE position or when a gear has been
selected manually.
Clutch - Low/Reverse
The low/reverse clutch holds the
reverse/overdrive carrier assembly to the
transaxle case when the transaxle is shifted into
the R and 1 positions. The low/reverse clutch is a
multi-disc clutch. It is splined to the transaxle
case.
Clutch - Forward One-Way Item Part Description
The forward one-way clutch is a sprag-type, one- Number
way clutch. The forward one-way clutch 1 - Gasket, pump body separa-
combines with the forward clutch to connect the tor
turbine shaft assembly to the low/intermediate
sun gear assembly in first, second and third 2 - Shaft, pump drive
gears. The forward one-way clutch always 3 - Seal, pump support (6 req'd)
overruns in all coasting operations and in fourth
gear. 4 - Support assy, pump
Clutch - Low One-Way 5 - Body, pump assy
The low one-way clutch is a roller type one-way 6 - Seal, pump
clutch which enables the transaxle case to hold
7 - Gears, pump
the reverse/overdrive carrier stationary when the
transaxle is in first gear. The low one-way clutch 8 - Insert, pump drive gear
holds the reverse/overdrive carrier assembly
9 - Plate, pump body separator
during acceleration. When coasting, the low one-
way clutch will overrun, disconnecting the final Pump
drive from the planetary gearset.
The pump provides the volume of liquid required
Hydraulic System to charge the torque converter, main control
valve body, cooling system, lubrication system
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307-01A-29 Automatic Transmission/Transaxle — Vehicles With: 307-01A-29
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

and hydraulic actuating components. The input signals are shared. Some inputs come from
transaxle uses a positive displacement gear and sensors (mass air flow meter, coolant
crescent-type pump which is shaft-driven by the temperature sensor etc.) and inform the PCM
torque converter. about the load status and the operating
conditions of the engine. Other inputs are based
Fluid Level and Filter
on driver inputs, such as accelerator pedal
Fluid from the oil pan area (formed by the position which is relayed to the PCM by the
transaxle case and converter housing) flows throttle position (TP) sensor. Other inputs again
through a filter to the oil pump. The filter has a come from the transmission itself, from sensors
recirculation port connected to the main control like the vehicle speed sensor (VSS), the
area of the case. It receives fluid from the main transmission range sensor (TR) (controlled by the
regulator exhaust. This provides fluid under position of the gear lever) and the transmission
pressure to aid the pump in higher efficiency fluid temperature sensor (TFT)
operation. A fluid control valve prevents foaming
Using all these input signals, the PCM can
of fluid by maintaining an oil pan level below the
determine when the time and conditions are right
rotating components. The two piece chain drive
for a shift or converter clutch application. The
cover prevents foaming by not allowing the chain
PCM can also determine the line pressure
to rotate in the fluid. A magnet on the underside
needed to optimize shift feel. In order to carry out
of the chain cover collects unwanted magnetic
these functions, the PCM controls five electronic
material.
solenoid valves - two ON/OFF solenoid valves for
Main Control switching, one pulse-width modulated (PWM)
The main control body contains the hydraulic solenoid valve for controlling the lock-up clutch,
solenoid valves. These valves direct fluid flow, one electronic pressure control (EPC) solenoid
restrict fluid flow and change fluid pressure. The valve for regulating the line pressure and a 3-2
main control receives signals from the solenoid shift timing/coast clutch solenoid valve for
valve body and changes those signals into controlling the disengagement of the coast clutch
hydraulic actions. These actions control the and the co-ordinated disengagement of the direct
operation of the hydraulic clutches and the clutch and the actuation of the low-intermediate
intermediate and overdrive band assembly. They brake band during a 3-2 shift.
also supply lubrication to the transaxle. Powertrain Control Module (PCM) - Inputs
Servo - Low/Reverse – Transmission fluid temperature (TFT) sensor
The low/reverse servo cushions the application of – Transmission range (TR) sensor
the low/reverse clutch when the transaxle is – Brake on/off (BOO) switch
shifted to reverse gear. – Electronic ignition (EI) system
Servo - 2-4 - Crankshaft position (CKP) sensor
The 2-4 servo cushions the shift feel during - Ignition control module
intermediate and overdrive band applications. – Mass air flow (MAF) sensor
Servo - Forward – Throttle position (TP) sensor
The forward servo cushions the application of the – Vehicle speed sensor (VSS)
forward clutch when the transaxle is shifted into – Transmission control switch (TCS)
D2 or 1. – Air conditioning (A/C) Clutch
Transaxle Electronic Control System – Engine coolant temperature (ECT) sensor
Electronic System Description – Turbine shaft speed (TSS) sensor

The gearshift timing, gearshift pressure (line Powertrain Control Module (PCM) - Outputs
pressure) and the solenoid valves of the torque – Transaxle solenoid body assembly
converter lock-up clutch (TCC solenoid valve) in
the CD4E transmission are controlled
electronically by the powertrain control module
(PCM) with its network of inputs and outputs. The
transaxle control is separate from the engine
control strategy in the PCM, although some of the

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307-01A-30 Automatic Transmission/Transaxle — Vehicles With: 307-01A-30

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

- Shift solenoid 1 (SS1) - Solenoid valve, torque converter lock-up
- Shift solenoid 2 (SS2) clutch (TCC solenoid)
- Solenoid valve, electronic pressure control - 3-2 Timing/coast clutch solenoid (3-
(EPC solenoid) 2T/CCS)
– Transmission control indicator lamp (TCIL).

PCM inputs

Item Part Description

Item Part Description Number
Number
2 Powertrain control module
1 Throttle position sensor (PCM)

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307-01A-31 Automatic Transmission/Transaxle — Vehicles With: 307-01A-31
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
3 Electronic ignition (EI) 7 Mass air flow (MAF) sensor
4 Transmission control switch 8 Engine coolant temperature
(TCS) (ECT) sensor
5 Transmission control indica- 9 Air conditioning clutch
tor lamp (TCIL)
10 Output speed sensor (OSS),
6 Stop lamp switch vehicle speed sensor (VSS)

Component Location

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307-01A-32 Automatic Transmission/Transaxle — Vehicles With: 307-01A-32

4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Brake, on/off (BOO) switch
Number The BOO switch signals the PCM when the
1 - Transmission range (TR) brakes are applied. The BOO switch is closed
sensor when the brakes are depressed and open when
they are released. The BOO switch will also
2 - Vehicle speed sensor (VSS) disengage the torque converter clutch (TCC)
3 - Turbine shaft speed (TSS) when the brake is applied.
sensor Symptoms: Failed ON - TCC will not engage at
less then 1/3 throttle.
4 - Shift solenoid assembly
Failed OFF or not connected - TCC will not
5 - Shift solenoid 1 (SS1)
disengage when brake is applied.
6 - Shift solenoid 2 (SS2) DTC: P0703, P1703
7 - Solenoid valve, torque con- Engine Coolant Temperature (ECT) Sensor
verter lock-up clutch (TCC
solenoid) The ECT sensor detects the engine coolant
temperature and sends this information to the
8 - 3-2 Timing/coast clutch so- PCM. The PCM uses the ECT sensor to control
lenoid (3-2T/CCS) the operation of the torque converter lock-up
9 - Solenoid valve, electronic clutch (TCC).
pressure control (EPC sole- Symptoms: TCC will always be OFF if ECT
noid) sensor reads colder than normal, resulting in
10 - Transmission fluid tempera- reduced fuel economy.
ture (TFT) sensor DTCs: P0116, P0117 and P0118
11 Output speed sensor (OSS) Electronic Ignition (EI) System

Powertrain Control Module (PCM) The electronic ignition system consists of the
PCM, a crankshaft position (CKP) sensor and
The operation of the transmission is controlled by one multi-tower ignition coil. The CKP sensor
the PCM. Input sensors send information to the sends a crankshaft position signal to the PCM.
PCM. The PCM then controls the solenoid valves The PCM then sends the appropriate ignition
that influence the operation of the transmission. signal to the ignition coil. The PCM uses this
DTCs:P0300 through P0308, P0320, P0340, and signal in the transaxle shift strategy, as well as
P1351 through P1364 torque converter clutch (TCC) control and
electronic pressure control. Wide open throttle
Air conditioning (A/C) clutch (WOT) shift control is also affected by the EI
The A/C switch is located on the suction system input.
accumulator/drier of a factory-installed air Symptoms: Harsh engagements and shifts, late
conditioning system. When the air conditioning WOT shifts, and no TCC engagement.
clutch cycling switch contacts close, the PCM
receives a signal voltage from the A/C switch DTCs: P0300 through P0308, P0320, P0340,
indicating that the A/C compressor clutch is P1351,P1357 through P1364
engaged. The PCM uses the A/C clutch cycling Mass Air Flow (MAF) Sensor
switch signal to adjust line pressure to
compensate for the additional engine load. The MAF directly measures the air mass flowing
into the engine. The output from the MAF sensor
Symptoms: With a faulty (closed) air conditioning is an analog DC signal between approx. 0,5 and
compressor clutch switch, the line pressure with 5,0 V, and it is used by the PCM to calculate the
the air conditioning switched off is slightly low. If injection pulse duration for the air/fuel mixture.
there is a malfunction in the opening of the air For transmission operations the MAF is used for
conditioning compressor clutch switch, the line the electronic pressure control (EPC), the control
pressure with the air conditioning switched on is of the gearshift timing and the control of the
slightly high. torque converter lock-up clutch.
DTC: P1460

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307-01A-33 Automatic Transmission/Transaxle — Vehicles With: 307-01A-33
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Symptoms: Incorrect gearshift timing, EPC Vehicle Speed Sensor (VSS)
pressure high or low, incorrect engagement of
The VSS is a magnetic pickup that sends a signal
the TCC, as well as symptoms that are similar to
to the PCM. This VSS signal informs the PCM
a fault on the throttle position (TP) sensor.
about the vehicle speed. It is used to determine
Malfunction indicator lamp (MIL) on.
the gearshift timing and the electronic pressure
DTCs: P0102, P0103, P1100, P1101 control (EPC).
Transmission Control Switch (TCS) Symptoms: Fixed shift feel, abnormal gearshift
timing and possibly unexpected downshifts with
The transmission control switch is a push-button
the throttle valve closed. No fourth gear. No
switch. When the transmission control switch is
engine braking in second or third gear. No
pressed, a signal is sent to the PCM. The PCM
engagement of the torque converter lock-up
then energizes the transmission control indicator
clutch (TCC). May flash the transmission control
lamp (TCIL) and engages or disengages fourth
indicator lamp (TCIL).
gear operation and provides coast braking in
second and third. DTC: P0500,P0503, P1500, P1501, P1503
Symptoms: No overdrive cancel when switch is Transmission Fluid Temperature (TFT) Sensor
cycled.
The TFT sensor is a thermistor (temperature
DTC: P1780 dependent resistor) which is located on the
solenoid valve body. The resistance value of the
Transmission Control Indicator Lamp (TCIL)
TFT sensor will vary with temperature. The PCM
The TCIL is located in the instrument panel and monitors the voltage across the TFT sensor to
is labeled O/D OFF. The transmission controls determine the temperature of the transmission
switch (TCS) controls the ON/OFF operation of fluid. The PCM uses this signal to determine the
the TCIL. When the driver initially presses the gearshift timing and to regulate the line pressure
TCS button, the TCIL comes ON to indicate that for operation under hot and cold temperatures. In
transaxle operation in fourth gear is disabled. addition, the PCM disables the operation of the
When the driver presses the TCS again, the TCIL torque converter lock-up clutch (TCC) at low
goes off. transmission temperatures and adjusts the
Symptoms: If the TCIL fails ON or OFF, the driver pressure of the electronic pressure control (EPC)
may have an incorrect indication of transaxle to the temperature.
operation. Symptoms: Improper TCC operation and EPC
DTCs: None pressure.

Throttle Position (TP) Sensor DTCs: P0712, P0713, P1711, P1783

The TP sensor is a potentiometer mounted on Transmission range (TR) sensor

the throttle body. The TP sensor detects the The PCM sends a voltage signal to the TR
position of the throttle plate and sends this sensor. The TR sensor contains a series of
information to the PCM as a varying voltage resistors that act as a voltage divider. The PCM
signal. monitors this voltage which corresponds to the
If there is a fault in the circuit of the TP sensor position of the transmission range selector lever
then the PCM detects that the TP sensor signal is (P, R, N, D, 2, 1) to determine desired gear and
outside the measuring range. The PCM then electronic pressure control (EPC) pressure. The
operates the transmission with a higher EPC TR sensor is located on the transmission and
pressure to prevent damage to the transmission. also incorporates the circuits for neutral/start and
The PCM also uses this signal to determine the the reversing lamps.
gearshift timing and for control of the EPC and Symptoms: Harsh engagement and fixed
the TCC. gearshift pressure. Engine will possibly not crank.
Symptoms: Harsh engagement, fixed gearshift Possible downshift. Operation in second or third
pressure, abnormal gearshift timing, TCC will not gear. Transmission does not display the correct
engage, TCC switchover. Malfunction indicator gear. No operation in fourth gear, no manual first
lamp (MIL) on. gear.

DTCs: P0122, P0123, P1120, P1121, P1124, DTCs: P0707, P0708, P1705
P1125 Turbine Shaft Speed (TSS) Sensor

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4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

The TSS sensor is an inductive sensor which Symptoms: Failed ON - minimum EPC pressure
sends a signal to the PCM indicating the input (minimum transmission torque capacity). May
speed of the turbine shaft. This signal is used to flash the TCIL.
control the torque converter lock-up clutch (TCC).
Failed OFF - maximum EPC pressure, harsh
It is also used to determine the setting of the
engagements and harsh shifts.
static pressure of the electronic pressure control
(EPC) during gearshifts. Fault codes: P1746, P1747 - Check output
circuit; is only caused by electrical fault.
Symptoms: No power flow through the torque
converter or harsh shifts. No fourth gear Torque converter lock-up clutch (TCC) solenoid
operation and engine braking in second and third valve
gear. May flash the TCIL. The TCC solenoid valve is controlled by pulse-
DTC: P0715 width modulation (PWM). It controls the
engagement and disengagement of the bypass
Output speed sensor (OSS)
clutch in the torque converter. The pressure in
The OSS sensor is an inductive sensor that the S4 circuit varies due to the pulse width
detects the speed of the park gear or the drive modulation of the TCC solenoid valve, thus
sprocket. The signal describes the speed of the modulating engagement and disengagement of
output shaft of the automatic transmission and is the bypass clutch in the torque converter.
evaluated by the PCM. The PCM uses the output
Symptoms: Failed ON - Engine stalls in manual
shaft speed together with other signals to
second. Engine lugging, poor performance at low
determine the gearshift timing.
engine speeds, harsh shifts.
Solenoid Valve Body Assembly
Failed OFF - Poor fuel economy, overheating,
The solenoid valve body assembly contains the TCC will not engage.
transmission fluid temperature sensor (TFT)
DTCs: P0741, P1742, P1743, P1744 May also
sensor, as well as five PCM controlled output
be generated by other non-electronic related
devices:
transmission hardware conditions.
– Electronic pressure control (EPC) solenoid
Fault codes: P0743, P1767 - Check output
– Shift solenoid 1 (SS1) circuit; is only caused by electrical fault.
– Shift solenoid 2 (SS2)
3-2 Timing/Coast Clutch Solenoid (3-2 T/CCS)
– 3-2 timing/coast clutch solenoid (3-2 T/CCS)
The 3-2 T/CCS is a variable force style (VFS)
– Torque converter lock-up clutch (TCC)
solenoid. The VFS type solenoid is an electro-
solenoid valve hydraulic actuator combining a solenoid and a
The PCM controls the operation of the transaxle regulating valve. It supplies pressure to the S3
through wiring to the solenoid valve body circuit to control the release of the direct clutch
assembly mounted on the main control assembly. and to apply the intermediate and overdrive band
The PCM cable is connected to the solenoid during a 3-2 downshift. The solenoid also
valve body on the top of the transmission regulates the pressure in the S3 circuit to control
housing. In the event of faulty components the the application and release of the coast clutch.
solenoid valve body should always be renewed Symptoms: Failed ON - no engine braking
as an entire unit.
(except in fourth gear), delayed 3-2 downshifts.
Electronic pressure control (EPC) solenoid Failed OFF - engine braking in second/third
The EPC solenoid is a variable force style (VFS) gears, firm or flared 3-2 downshifts, harsh 4-3
solenoid. The VFS solenoid is an electro- downshifts.
hydraulic actuator combining a solenoid and a Fault codes: P1788, P1789 - Check output
regulating valve. The solenoid provides electronic
circuit; is only caused by electrical fault.
pressure control (EPC) which regulates line
pressure (LP) and the line modulator pressure Shift Solenoid Assembly (SS1, SS2,SS3)
(LM). This is controlled by producing a resisting Shift solenoids 1 and 2 provide gear selection of
pressure to the main regulator and line modulator first through fourth gears by providing ON/OFF
circuits. The LP and LM pressures control the pressure control to the shift valves.
clutch application pressures.

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307-01A-35 Automatic Transmission/Transaxle — Vehicles With: 307-01A-35
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

SS1 Symptoms: Improper gear selection
depending on failure mode and transaxle range
selector lever position; refer to Shift Solenoid
Application Chart No. 701.
Fault codes: P0731, P0734, P0750, P0751,
P1751 - Check output circuit; is caused by
electrical fault. May also be generated by other
non-electrical related transmission hardware
conditions.
SS2 symptoms: Incorrect choice of gear
depending on fault mode and position of the gear
lever; refer to table "Shift Solenoid Operation
Chart".
Fault codes: P0733, P0755, P0756, P1756 -
Check output circuit; is caused by electrical fault.
May also be generated by other non-electrical
related transmission hardware conditions.
OTHER CONCERNS: SHIFT SOLENOID
OPERATION CHART
Solenoid Operation
The following solenoid operation chart shows
normal solenoid operation for given operating
modes.

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307-01A-36 Automatic Transmission/Transaxle — Vehicles With: 307-01A-36
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

Diagnostic Strategy
DIAGNOSIS AND TESTING

To properly diagnose a concern have the

following publications available:
Special Tool(s) – OASIS massages
Alignment Gauge, – Technical Service Bulletins (TSBs)
Transmission Range Switch – Wiring Diagram
307-271 (17050A) Preliminary Inspections and Diagnosis:
Proceed according to the following diagnosis flow
chart.
Hydraulic Pressure Gauge – Know and understand the customer's
concern.
307-132 (17014)
– Verify the concern by operating the vehicle.
– Check fluid level and condition.
– Check the adjustment of the TR sensor.
Connector, Pressure Test – Check whether any additional accessories
have been installed after the vehicle was sold
307-132-02 (1701402) (and whether they have been installed
correctly), for instance air conditioning, car
telephone, cruise control system, trip
computer, additional stop lamp.
Plate, Compressed Air – Check shift linkages for proper adjustment.
Transmission Test – Check TSBs and OASIS messages for the
307-301 (17056) concern.
– Interrogate the trouble codes both in a test
with the engine running (KOER) and in an
engine-OFF test (KOEO). Note the displayed
NOTE: Do not take short cuts or assume that trouble codes.
critical adjustments have already been made.
NOTE: Follow the procedure as written to avoid
missing critical components or steps.
Test Result Remedial action
1) Were any current trouble Yes Rectify the cause(s) for the trouble code(s) (follow the
codes recorded? menu in WDS or FDS2000).
No Proceed to the Symptom Chart. Then continue with step
5.
2) Were any stored trouble Yes Delete the trouble codes and road test the vehicle.
codes displayed?
No Continue with step 4.
3) Are any stored trouble codes Yes Rectify the cause(s) for the trouble code(s) (follow the
displayed? menu in WDS or FDS2000), then continue with step 4.
No Continue with step 4.
4) Is the fault rectified? Yes Repeat the test with the engine running and the engine-
OFF test and verify that no trouble codes are displayed.
Delete any stored trouble codes. Deliver the vehicle.
No Proceed with the symptom chart.
5) Is the fault is temporarily rec- Yes Switch the diagnostic unit to the ""Data Logger" function
tified while FDS2000 or WDS is and locate any intermittent faults.
connected up?
No Continue with step 6.

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307-01A-37 Automatic Transmission/Transaxle — Vehicles With: 307-01A-37
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Test Result Remedial action
6) Is the fault rectified? Yes Repeat the test with the engine running and the engine-
OFF test and verify that no trouble codes are displayed.
Delete any stored trouble codes. Deliver the vehicle.
No Inform the Hotline.

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307-01A-38 Automatic Transmission/Transaxle — Vehicles With: 307-01A-38
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

Preliminary Inspection

– Engine cold or at operating temperature

– Hot or cold ambient temperature
Preliminary Inspection
– Type of road
WARNING: Apply the handbrake and – Vehicle loaded/unloaded
move the selector lever to "P" when – City/highway driving
– the vehicle is parked; – Upshift
– any checks or adjustments are carried out in – Downshift
the engine compartment;
– Coasting
– the vehicle is left with the engine running.
– Shift quality
Know and Understand the Concern
– Noise/vibration
The customer concern must be clearly
understood before diagnosing the cause of the
fault. Therefore it is important to check the details Fluid Level Check
with the customer. The conditions under which
the concern arises must be understood. For NOTE: If the vehicle has been operating for an
example: extended period at high speeds or in city traffic
during hot weather or pulling a trailer, the engine
– Engine cold or at operating temperature should be turned off for about 30 minutes to allow
– hot or cold ambient temperature the fluid to cool before checking.
– vehicle operating conditions The fluid levels should preferably be checked at
operating temperature (60-70°C) after a drive of
approx. 30 km. If necessary, it is also possible to
verify customer concern by driving the check the fluid levels without driving 30 km,
vehicle provided the ambient temperature is above 10°C.
NOTE: If noise/vibration is a concern, check for With the vehicle on a level surface, start the
dependency on: rpm, vehicle speed, shift, gear engine and move the transmission range selector
range or temperature. lever through all of the gear ranges, allowing
NOTE: Some CD4E automatic transmissions sufficient time for each position to engage.
may give rise to concern over the way the engine Engage the transmission range selector lever in
runs. For example, it can cause the engine to the PARK position, fully set the parking brake
stall if the torque converter lock-up clutch does and leave the engine running at idle.
not disengage.
Wipe off the fluid level indicator cap, pull the fluid
level indicator out and wipe clean. Put the fluid
level indicator back into the guide tube and make
sure it is seated properly. Pull out the fluid level
indicator and read the fluid level.
When checking the fluid levels at operating
temperature (60-70°C), the fluid level should be
in the shaded range on the dipstick. When the
vehicle has been driven, and the outside
temperature is above 10 °C, the fluid level should
be between the hole and the lower edge of the
shaded area on the fluid level indicator.

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307-01A-39 Automatic Transmission/Transaxle — Vehicles With: 307-01A-39
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Transmission Fluid Indicator Reading Add Fluid

Item Part Description

CAUTION: Use of any fluid other than
Number
that specified could result in
1 - Max. mark transmission malfunction or failure.
2 - Min. mark Before adding any fluid, be sure that the correct
type (ESP-M2C166-H) will be used.
3 - Lower hole mark, DO NOT
DRIVE Add transmission fluid through the filler tube in
amounts of 0,25 l, each time checking the fill
level on the fluid dipstick. Drain automatic
transmission fluid if too much is filled.
High or Low Fluid Level
If the fill level is too high, transmission
components may cause the fluid to foam. Fluid Change - Drain/Refill
Foamed oil causes variable operating pressure,
1. Raise the vehicle.
with the following consequences:
2. Place a suitable container under the
– harsh/delayed shifts or engagements transmission drain plug.
– damage to the clutch material NOTE: If internal damage to the transmission is
– incorrect torque converter operation suspected, drain the fluid through a paper filter. A
– fluid emission from the vent small amount of abraded clutch particles is a sign
of normal wear. If however a larger amount of
If fluid level is too high, excess fluid must be particles of abraded clutch or metallic pieces are
removed. Refer to Fluid Change - Drain/Refill in found, then a transmission repair is necessary.
this section for proper procedures.
A fluid level that is too low will affect transmission
operation, as follows:
– slipping
– delayed engagement
– damage to transmission components
Low levels may also indicate that a leak is
present in the fluid system.
If the fluid level is too low, fluid must be added.
Refer to Add Fluid in this section.

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307-01A-40 Automatic Transmission/Transaxle — Vehicles With: 307-01A-40

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

3. Remove the transmission drain plug and 12. Install the transmission drain plug.
drain the transmission fluid. 13. Remove the drain pan, tools and
4. Install the transmission drain plug. materials and lower the vehicle.
5. Lower the vehicle. 14. Fill the automatic transmission with
6. Fill the automatic transmission with automatic automatic transmission fluid according to
transmission fluid according to Ford Ford specification ESP-M2C166-H.
specification ESP-M2C166-H. For further 15. Start the engine and move the shift lever
information, refer to the following operation in through all positions. Check the fluid level
this section: Specifications and top up if necessary.
7. Apply the handbrake. Start the engine and
run it at idle speed for five minutes while
shifting through all shift lever positions. Fluid Condition Check
Switch off the engine. NOTE: Evidence of fluid contamination or
8. Raise the vehicle. incorrect fluid can cause poor shift quality. If the
9. Place a suitable container under the transmission fluid condition is suspect, drain the
transmission drain plug. transmission and refill with automatic
10. Remove the transmission drain plug and transmission fluid to Ford specification ESP-
drain the transmission fluid. M2C166-H .
11. After the fluid has been drained, clean the – Make the normal fluid level check as
drain plug thread and apply a thin coat of described in Fluid Level Check in this section.
Teflon Sealant meeting Ford specification – Observe the color and odor of the fluid. It
WSK-M2G350-A2. should be red, not brown or black. If there is
an odor, this may indicate overheating or
damage to a clutch disc or band.
– Wipe the dipstick with a clean lint-free cloth.
Check the resulting mark for signs of solid
particles or anti-freeze (sticky residues on the
dip-stick).
If particles are present in the fluid or there is
evidence of contamination, the transmission drain
plug should be removed and a sample of filtered
through a paper filter examined. If transmission
failure is confirmed by further evidence of coolant
or excessive particles in the fluid, the
transmission must be completely cleaned and
repaired. This includes cleaning and flushing the
torque converter and transmission cooling
system. During disassembly and assembly, all
overhaul checks and adjustments of clearances
and end play must be made.
After repairing the transmission, all diagnostic
tests and adjustments listed in the diagnosis
section must be completed to make sure that the
problem has been eliminated.

Transmission range (TR) sensor

Check the adjustment of the TR sensor.

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307-01A-41 Automatic Transmission/Transaxle — Vehicles With: 307-01A-41
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Road Test Check shift linkages for proper adjustment.
The road test verifies that the shift control system REFER to Section 307-05A / 307-05B.
is operating correctly.
1. Run the engine and automatic transmission
up to normal operating temperature.
2. Move selector lever to "D".
3. Gently depress the accelerator pedal and
check the vehicle speed at which the
automatic transmission upshifts and the
converter lock-up clutch engages.
4. If the transmission is in 4th gear (overdrive),
actuate the O/D shut-off. The transmission
should downshift to 3rd gear. Remove foot
from accelerator. Engine braking should
occur while coasting.
5. Depress the accelerator pedal to the floor.
The transmission should downshift into 1st
gear or 2nd gear, depending on vehicle
speed.
6. With the selector lever in position "D", driving
at a speed greater than 80 km/h and with the
accelerator pedal pressed about 1/3 of the
way down, move the selector lever to
position "2" and lift the foot from the
accelerator pedal. The transmission must
immediately change down into 2nd gear.
7. With the vehicle in 2nd gear, move the
selector lever to range "1". Release the
accelerator pedal. The transmission should
downshift to 1st gear at speeds below 48 to
56 km/h.

Shift Points in relationship to Vehicle Speed

Max. Speed Min. Speed
Gearshift km/h km/h
Min 1-2 24 15
Min 2-3 34 24
Min 3-4 56 47
CT 4-3 53 44
CT 3-2 23 13
CT 3-1 23 13
CT 2-1 23 13
PT 1-2 34 24
PT 2-3 60 50
PT 3-4 85 72
WOT 1-2 61 50
WOT 2-3 110 100
WOT 3-4 169 159
Min = accelerator pedal depressed slightly, CT =
Closed Throttle, PT = Part Throttle (half way down)
WOT = Wide Open Throttle

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307-01A-42 Automatic Transmission/Transaxle — Vehicles With: 307-01A-42
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

Diagnostics

2. Remove the intake pipe with the air cleaner.

On-Board Diagnosis with the Diagnostic Tool 1. Detach the positive crankcase ventilation
NOTE: All engine checks must be completed and hose.
any faults rectified before any transmission 2. Disconnect the air cleaner outlet pipe.
checks may be carried out. • Pull the air cleaner housing out of the
When using the roller test stand, make sure that rubber bush.
the vehicle is secured.

Preparation
WARNING: Do not carry out the test on a
lift as the vehicle may move out of
position as result of sudden gearshifts.
Down-load the required software according to the
manufacturer's instruction.
To carry out the diagnosis, follow the user guide
instructions on the PDU display.

Connecting the Diagnostic Tool 3. Lay the wiring so that it is not caught when
CAUTION: All wiring, including that of the the bonnet is closed.
pressure test gauge, should be laid at a
safe distance from any source of heat.
1. Remove the intake pipe together with the air
filter housing.
1. Disconnect the mass air flow (MAF) sensor
plug.
2. Disconnect the intake air temperature (IAT)
sensor plug.
3. One bolt, two nuts.

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307-01A-43 Automatic Transmission/Transaxle — Vehicles With: 307-01A-43
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

4. Disconnect the CD4E transmission plug. 7. Connect the test lead to TSS sensor and
secure the wiring loom plug with a suitable
retaining strap.

5. Connect the test lead to the automatic

transmission.
1. Connect test lead. 8. Install the intake pipe together with the air
2. Secure the wiring loom plug with a filter housing.
retaining strap. 1. Fit the PCV hose.
2. Connect the intake hose.

6. Pull out the plug of the turbine shaft speed

(TSS) sensor.

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307-01A-44 Automatic Transmission/Transaxle — Vehicles With: 307-01A-44

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

9. Install the intake pipe together with the air 11. Connect the Diagnostic Tool interface
filter housing. cable to the engine management serial
1. Connect the mass air flow (MAF) sensor communications link (SCL) plug.
multiplug.
2. Connect the intake air temperature (IAT)
sensor multiplug.
3. Fit the bolt and the two nuts.

NOTE: The software must be loaded.

12. Lay all the wiring in the vehicle, connect it
and close the hood (right-hand side shown).

10. Connect the VBA extension lead to the

vehicle battery.

13. Connect the red test probe lead to the

switch.

Perform On-board Diagnosis

A passenger is necessary because the screen
data must be read from the PDU during the
journey.
During diagnostics with the Diagnostic Tool, the
electrical connection between the transmission
and the PCM is disconnected. All gear changes
are then controlled by the Diagnostic Tool.

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307-01A-45 Automatic Transmission/Transaxle — Vehicles With: 307-01A-45
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

CAUTION: The operating pressure will transmission then changes automatically to 3rd
drop to a minimum during certain test gear, and the coast clutch is disengaged. Other
steps. The PDU will interrupt some tests gears may be selected as required.
during acceleration in order to prevent Continue the diagnostic procedure until its
transmission damage. completion, then carry out any rectification work
The checks may be interrupted at any time by and re-verify the condition (by a road test if
switching the PDU off (red button). The necessary).
DIAGNOSTIC TROUBLE CODE CHART

DIAGNOSTIC TROUBLE CODE CHART

DTC: Component Possible cause Symptom
P1116 ECT sensor. Voltage of ECT sensor not Repeat self-test at operating temperature.
within tolerance range.
P0117 ECT sensor. ECT sensor signals 125 °C Torque converter lock-up clutch perma-
(254 °F). nently disengaged.
P0118 ECT sensor. ECT sensor signals -40 °C (- Torque converter lock-up clutch perma-
40 °F). nently disengaged.
P1124 TP sensor. Voltage of TP sensor not TP sensor not in the correct position dur-
within tolerance range. ing the self-test (repeat self-test).
P0122, TP sensor. See Engine Management Harsh gearshifts, incorrect gearshift tim-
P0123, VSTM. ing, converter lock-up clutch permanently
P1120, disengaged
P1121,
P1125
P0102, MAF See Engine Management Incorrect gearshift timing, faulty operating
P0103, VSTM. pressure, converter lock-up clutch en-
P1100, gages at incorrect time, same symptoms
P1101 as for faulty TP sensor
P0300, Engine Ignition See Engine Management Converter lock-up clutch not engaging,
P0308, VSTM. delayed downshift at full throttle.
P0320,
P0340,
P1351,
P1364
P1705 TR sensor TR sensor not in position ""P" Repeat self-test as required.
during self-test
P1703 BPP switch BPP switch not activated dur- Torque converter lock-up clutch not en-
ing self-test (possibly open cir- gaging with throttle valve less than 1/3
cuit). open.
P1703 BPP switch Faulty BPP switch circuit. Torque converter lock-up clutch not dis-
engaging under braking.
P1460 A/C switch A/C clutch switched on during Faulty operating pressure.
self-test
P0750* SSA solenoid SSA solenoid circuit Incorrect gear selection (see Solenoid
Operation Chart).
P0755* SSB solenoid SSB solenoid circuit Incorrect gear selection (see Solenoid
Operation Chart).
P1747*, EPC solenoid Voltage fluctuations in EPC If short circuit to ground: engine speed
P1760 solenoid circuit, short circuit to limitation (partial fuel shut-off, heavy mis-
ground firing)

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307-01A-46 Automatic Transmission/Transaxle — Vehicles With: 307-01A-46

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

DTC: Component Possible cause Symptom
P1746* EPC solenoid Voltage fluctuations in EPC Open circuit causes high operating pres-
solenoid circuit, open circuit sure, juddering gearshifts and engage-
ment.
P1711 TFT sensor Transmission not at operating tempera-
ture during self-test (bring up to operating
temperature and repeat self-test as re-
quired).
P0713 TFT sensor sig- Abnormal engagement and
nals temperature disengagement of converter
below -40 °C (- lock-up clutch, faulty operating
40 °F) or open pressure control.
circuit.
P0712 TFT sensor TFT sensor signals tempera- Abnormal engagement and disengage-
ture above 150 °C (302 °F) or ment of converter lock-up clutch, faulty
short circuit. operating pressure control
P0715 TSS sensor PCM detects missing signal No engagement of converter lock-up
from TSS sensor. clutch, harsh gearshifts. No 4th gear and
no engine braking in 2nd or 3rd gear.
P0731** SSA, SSB sole- None. 1st gear Incorrect gear selection (see Solenoid
noid or mechani- Operation Chart).
cal components.
P0732** SSA, SSB sole- No 2nd gear. Incorrect gear selection (see Solenoid
noid or mechani- Operation Chart).
cal components.
P0733** SSA, SSB sole- No 3rd gear. Incorrect gear selection (see Solenoid
noid or mechani- Operation Chart).
cal components.
P0734** SSA, SSB sole- No 4th gear. Incorrect gear selection (see Solenoid
noid or mechani- Operation Chart).
cal components.
P0743* TCC solenoid No voltage at TCC solenoid If switched on incorrectly: engine stalls in
during self-test. manual 2nd gear, engine does not reach
high engine speeds, poor performance at
low engine speeds, harsh gearshifts.
P1780 O/D switch No switchover signal from O/D Repeat self-test.
switch during self-test.
P1783 TFT sensor TFT sensor signals tempera- Operating pressure too high
ture above 132 °C (270 °F).
P0707 TR sensor Short circuit in TR sensor cir- No operation in 4th gear, fixed gearshift
cuit. pressure. No manual 1st gear
P0708 TR sensor Open circuit in TR sensor cir- No operation in 4th gear, fixed gearshift
cuit. pressure, no manual 1st gear.
P1789* 3-2T/CCS sole- Short circuit in 3-2T/CCS sole- No engine braking (except in 4th gear),
noid noid circuit during self-test. delayed 3-3 downshift.
P1788* 3-2T/CCS sole- Open circuit in 3-2T/CCS so- Engine braking function in 2nd and 3rd
noid lenoid circuit during self-test. gear, abrupt or rough 3-2 downshifts,
harsh 4-3 downshifts.
P1742 TCC solenoid TCC solenoid permanently Harsh gearshifts. Engine stalls at low ve-
engaged hicle speeds.
P1744 TCC solenoid Lock-up clutch slipping despite Torque converter lock-up clutch not en-
TCC solenoid being switched gaging, minimal operating pressure.
on.

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307-01A-47 Automatic Transmission/Transaxle — Vehicles With: 307-01A-47
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

DTC: Component Possible cause Symptom
P1751 SSA solenoid Mechanical or hydraulic fault in Incorrect gear selection depending fault
the SSA solenoid. mode and position of selector lever (TCIL
flashing).
P1756 SSB solenoid Mechanical or hydraulic fault in Incorrect gear selection depending on
the SSB solenoid. fault mode and position of selector lever
(TCIL flashing).
P0756 SSB solenoid Mechanical or hydraulic fault in Incorrect gear selection depending on
the SSB solenoid. fault mode and position of selector lever
(MIL flashing).
P0751 SSA solenoid Mechanical or hydraulic fault in Incorrect gear selection depending on
the SSA solenoid. fault mode and position of selector lever
(MIL flashing).
P0721 OSS sensor PCM receiving faulty OSS sig- Harsh gearshifts, incorrect gearshift tim-
nal. ing.
P0720 OSS sensor PCM receiving no signal from Harsh gearshifts, incorrect gearshift tim-
OSS sensor. ing.
P0722 OSS sensor PCM intermittently receiving Harsh gearshifts, incorrect gearshift tim-
no signal from OSS sensor. ing.
P1714 SSA solenoid Mechanical fault in the SSA Incorrect selection of gear depending on
solenoid. fault mode and position of the gear lever
(see Solenoid Operation Chart).
P1715 SSB solenoid Mechanical fault in the SSB Incorrect selection of gear depending on
solenoid. fault mode and position of the gear lever
(see Solenoid Operation Chart).
P0718 TSS sensor PCM receiving faulty signal Harsh gearshifts, no power flow through
from TSS sensor. torque converter.
P1702 TRS sensor PCM intermittently receiving Possibly incorrect gear selection by the
no signal from TRS sensor. PCM.
P1713 TFT sensor Signal from TFT sensor too High operating pressure, incorrect gear
low (= temperature too high). selection, harsh gearshifts, harsh en-
gagement.
P1718 TFT sensor Signal from TFT sensor too High operating pressure, incorrect gear
low (= temperature too low). selection, harsh gearshifts, harsh en-
gagement.
P1636 Induction strip See Engine Management VSTM.
labeling
P1782 P/E switch P/E switch not operated during See Engine Management VSTM.
self-test or open or short circuit
in P/E switch circuit
* Tests of output circuits are only triggered by
electrical symptoms. ** Can also be caused by other
non-electrical transmission components. Special Testing Procedures

Line Pressure Test

WARNING: When performing the stall

speed test, apply the handbrake fully and
press hard on the foot brake pedal.
Failure to observe these instructions can
result in an accident causing death or
serious injury.

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307-01A-48 Automatic Transmission/Transaxle — Vehicles With: 307-01A-48

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

CAUTION: Perform line pressure test If the line pressure at idle speed is too low, check
prior to performing static test. If line the following items:
pressure is low at stall, do not perform – Fluid level
static test or further transmission – Restricted inlet filter
damage will occur. Do not maintain WOT
in any gear range for more than five (5) – Loose main body
seconds. – Solenoid body
The transmission fluid level and engine coolant – Accumulator body to case bolts
level must be correct. Both fluids must be at – Excessive leakage in pump
normal operating temperature. Before carrying – Sticking main regulator valve
out the check, make sure the gearshift linkage is – Damaged inlet tube seal on inlet filter
set correctly.
– Damaged gaskets
1. Remove the main line plug and connect test – Damaged separator plate
gauge 307-132 (17-014) with adapter.
Line pressure at idle speed too high:

Line Pressure Plug – Carry out a visual check of the transmission

wiring loom.
– Carry out diagnosis using the Diagnostic
Tool.

Static Test
CAUTION: If the operating pressure at
idle is too low, do not carry out the static
test.
The static test checks the operation of the
following components:
– Forward clutch
Item Part Description – Low/Reverse Clutch Assembly
Number – Reverse clutch
A - Line Pressure Plug – Engine power output
2. Start the engine and measure the line Transmission fluid level and engine coolant level
pressure (see table). must be correct. Both fluids must be at normal
operating temperature.
Operating pressure CAUTION: This test must not be
Transmission continued for longer than 5 seconds
Range Operating Operating after the engine speed reading has
Selector pressure at pressure at stabilized.
Lever idle speed stall speed
Position (bar) (bar) CAUTION: If engine rpm recorded by the
P-N 4,4-5,2 - tachometer exceeds maximum specified
R 4,4-5,2 18-20 rpm, release accelerator pedal
D 3,1-3,6 11,6-12,7 immediately. Clutch or band slippage is
indicated.
2 3,1-3,6 11,6-12,7
1 3,1-3,6 11,6-12,7

Permitted stall speed

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307-01A-49 Automatic Transmission/Transaxle — Vehicles With: 307-01A-49
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Engine Stall speed (1/min) 1. Drain off automatic transmission fluid.
1,8 Zetec 2150-2560 Remove main control cover.
2,0 Zetec 2315-2700 2. Remove the main control as an assembly
2,5 Duratec-VE 2325-2710 with the solenoid body assembly.
1. Connect the digital rev counter so that it can 3. The inoperative clutches may be located by
be easily read from the driver's seat. Apply applying air pressure into the appropriate
the handbrake fully and depress the clutch port; refer to Air Pressure Test Port
footbrake. Locations.
2. Start the engine. 4. Fit plate 307-301 (17-056) for the
transmission air pressure test with six bolts.
3. Move the selector to "D" and hold the
accelerator pedal in the full throttle position CAUTION: Compressed air must not be
(WOT) until the tachometer reading stabilizes applied to the coast clutch circuit at the
(max. 5 seconds). same time as it is applied to the forward
4. Read off the stall speed. clutch circuit. Failure to observe this
instruction can lead to the coast clutch
CAUTION: After testing move piston coming out of the forward clutch
transmission range selector lever to piston.
NEUTRAL (N) and run the engine at least
NOTE: "Clutch/brake band operation" table in
30 seconds with idle speed to allow
this sub-section.
torque converter to cool.
Stall speed too high:
– Selector lever position "D": Check forward
clutch.
– Selector lever position "R": Check reverse
clutch or low/reverse clutch
Stall speed too low:
– Check the powertrain control system.
A no-drive condition can exist even with correct
transmission fluid pressure because of
inoperative clutches or bands. Refer to the
clutch/band application chart to determine which
components may be responsible. A clutch
concern may be located by substituting air
pressure for oil pressure to determine the
location of the malfunction.
When the transmission range selector lever is in
a forward gear range (D, 2, 1), a no-drive
condition may be caused by an inoperative
forward clutch.

Test Procedures

Air Pressure Test

CAUTION: Perform this test only if the

transmission has been removed.
NOTE: Only perform this test when other test
procedures have brought you to this one.

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307-01A-50 Automatic Transmission/Transaxle — Vehicles With: 307-01A-50

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

5. Apply compressed air at 2,75 bar to the Air Pressure Test Results
relevant clutch connection (see 'Installation
If the clutch pistons are not working, clean them
positions of compressed air test
and search for the cause of the fault.
connections'). Either a dull knock can be
heard or the piston movement can be felt. If If a clutch is not operated when compressed air is
the clutch seals are leaking or the return applied to the corresponding bore, or if clutches
valve balls leaking, a hissing noise will be operate together, check the oil bores in the
heard. housing.
If application of air pressure to the pressure
Air Pressure Test Port Locations reservoir produces no operation, remove the
pressure reservoir and check the housing bores
and the pistons.

Leakage Inspection
Pull out the fluid level indicator and check the
color of the transmission fluid. The original
factory fill is red. This will make it easier to
determine whether the leak is on the engine or
the transmission. As long as the transmission has
not been topped up often and as long as no fluid
change has been performed, the red color of the
transmission fluid filled in production makes
location of leaks easier.
Leaks at the main control cover gasket can often
be cured by tightening the bolts of the main
control cover to 16 Nm. If necessary, renew the
main control cover gasket.
Check the fluid filler tube connection at the
transmission case. If leakage is found, install a
new fluid filler tube grommet.
Check the cooler lines and fittings between the
transmission and the cooler in the radiator for
looseness, wear or damage. If leakage cannot be
stopped by tightening a tube nut, renew the
damaged parts. When fluid is found to be leaking
between the case and the fluid tube connector,
Item Part Description check for a missing or damaged O-ring. Tighten
Number the fitting to the maximum specification.

1 - Reverse Clutch Test Port CAUTION: Do not try to stop the fluid
leak by increasing the torque beyond
2 - Forward Clutch Test Port specification. This may cause damage to
3 - Direct Clutch Test Port the case threads.

4 - Test connection - loosened If the leak continues, renew the fluid tube
position of 2/4 brake band connector and tighten to specification. Follow the
same procedure to eliminate fluid leaks between
5 - Test connection - tightened the oil cooler and the fluid tube connector.
position of 2/4 brake band
Check the engine coolant in the radiator. If
6 - Servo Apply Test Port transmission fluid is present in the coolant, the
cooler in the radiator is probably leaking.

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307-01A-51 Automatic Transmission/Transaxle — Vehicles With: 307-01A-51
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

The cooler can also be checked by disconnecting Check for fluid leaks between the pump and the
the fluid tubes from the tube connectors and transmission case. A leak may be due to a rolled
applying no more than 345 kPa of air pressure to pump lip seal or a damaged seal. If necessary,
the tube connectors. Remove the radiator cap to repair the oil pump.
relieve the pressure build up at the exterior of the
fluid cooler tank. If the oil cooler leaks and/or it
does not hold the pressure applied, install a new External Sealing
oil cooler.
The following components prevent external
If leakage is found at the transmission range leakage of transmission fluid from the CD4E
selector lever shaft, renew the shaft seal. automatic transmission:
Check for fluid leaking from the differential seal. – Gaskets
Leakage may result from a damaged seal, – Lip type seals
missing garter spring or worn front wheel
– O-rings
driveshaft or joint. Renew the seal and/or front
wheel driveshaft and joint, as necessary. – Seal rings.

Leakage Points

Item Part Description

Item Part Description Number
Number
4 - Seal Assembly - Converter
1 - Gasket - transmission Split Impeller Hub
Flange
5 - Seal - differential - converter
2 - Gasket - Pump Body Sepa- housing
rator
6 - Seal - differential - transmis-
3 - Gasket - Main Control Cover sion case

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307-01A-52 Automatic Transmission/Transaxle — Vehicles With: 307-01A-52

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Item Part Description Leakage Points
Number
7 - Seal - transmission range
selector lever shaft
8 - Seal - transmission range
switch
9 - Cover Assembly - Interme-
diate/ Overdrive Servo
10 - Plugs (1/4-18 conical thread)
(line pressure)
11 - Connector Assembly - 3/8-
18 Cooler Line Fitting (2
Req'd)
12 - Connector Assembly - 3/8-
18 Cooler Line Fitting (2
Req'd)
13 - Plug -1/2-14 Socket Square
Head (Drain Plug)
14 - Seal - Pump Assembly (O-
Ring)
15 - O-Ring - Torque Converter
Speed Sensor
16 - Seal - Speedo Retainer 1. Fluid leaking by the converter impeller hub
17 - Grommet - Fluid Filler Tube seal lip will tend to move along the drive hub
and onto the back of the impeller housing.
18 - Indicator Assembly - Fluid Unless the seal is totally destroyed, the fluid
Level leaking from around the seal lip will deposit
19 - Vent Ring near to the outer side of the case.
2. Fluid leaking around the outside of the
converter hub seal will follow the same path
as that leaking from the seal lip.
Fluid Leakage in Torque Converter Area
3. Fluid leakage from the welded metal
Locate leaks near the torque converter in the reinforcements for the converter-to-drive
following way. Leakage at the front of plate threaded pins will be evident on the
transmission, as evidenced by fluid around the outside of the converter, on the back of the
converter housing, may have several sources. drive plates and in the converter housing,
The cause can often be established before the near to the drive plate. If leakage is
automatic transmission is removed from the suspected in these areas, remove the torque
vehicle. The paths which the fluid can take to converter and carry out a pressure test.
reach the bottom of the converter housing are as 4. Fluid leakage from the pump will flow down
follows (numbers on illustration relate to items the back of the converter housing. Leakage
below): can be caused by loose or missing pump
bolts, a torn or damaged seal between the
pump and the housing and/or a worn pump
bearing bush.
5. Engine oil leaks are sometimes improperly
diagnosed as transmission pump seal leaks.
The following areas of possible leakage

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307-01A-53 Automatic Transmission/Transaxle — Vehicles With: 307-01A-53
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

should be checked to determine if engine oil of transmission fluid. These dyes help to
leakage is causing the concern. determine whether the leaks are of transmission
1. Oil leakage at the cylinder head cover fluid or engine oil, or whether the transmission
means that oil flows to the converter fluid is leaking from the cooler into the coolant. A
housing or leaks between the converter UV lamp is used to determine the presence of the
housing and the cylinder block, so that oil dyed transmission fluid.
is then found on or in the lower part of the
converter housing.
2. Oil leakage at the oil gallery plugs can Transmission Fluid Cooler
cause oil at the back of the cylinder block
to flow to the converter housing. CAUTION: If the automatic transmission
was dismantled to renew components or
3. Oil leakage and the rear crankshaft seal to remove foreign bodies from valves in
can cause oil to get to the drive plate and the valve body, then the torque converter
from there into the converter housing. and the transmission fluid cooler must
be cleaned with converter/oil cooler
cleaner no. 014-00028 or similar. Under
Further leakage tests no circumstances should an attempt be
If the previous leakage tests have not clearly made to clean the converter by hand with
shown the cause of the leak, perform the solvent.
following. If the transmission is worn or damaged internally,
1. Remove the converter housing. Remove abraded or metal particles from the clutch friction
traces of oil from the top and bottom of the plates or bands can get into the converter or
front side of the converter housing, the rear cooler. These foreign bodies are one of the main
of the engine and the oil sump. Clean the causes of automatic transmission faults. All
torque converter area with suitable non- contaminants must be removed from the system
flammable solvent and dry with compressed before a repaired automatic transmission is re-
air. installed.
2. Wash out or down the converter housing and
the front side of the drive plates. The
converter housing can be washed out using Transmission Fluid Cooler Flow Test
an oil can filled with a suitable detergent. NOTE: The transmission linkage adjustment,
Blow dry all washed areas with compressed fluid level and line pressure must be within
air. specification before performing this test. Refer to
3. Start the engine and run it until the automatic transmission linkage adjustment procedure. For
transmission fluid has reached operating transmission fluid level checking procedures,
temperature. Check the back of the cylinder refer to Check Fluid Level and Condition. For
block and the top of the converter housing for transmission line pressure testing procedures,
signs of leaks. Raise the vehicle. Run the refer to Line Pressure Test.
engine at fast speeds at first, then let it idle.
Increase the fluid pressure by frequently
putting the selector lever into DRIVE and
REVERSE. Observe the front of the drive
plate, the back of the cylinder block (if
possible) and all sides of the converter
housing. Run the engine until fluid leakage is
evident and the source of leakage can be
determined.

Leak Check Test With Black Light

Aniline and luminous dyes that can be dissolved
in the transmission fluid have been useful in
finding leaks. These are mixed in proportions of
2.5 ml (1/2 teaspoon) of dye powder to 0.23 liters

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307-01A-54 Automatic Transmission/Transaxle — Vehicles With: 307-01A-54

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

1. Pull the fluid level indicator out of the fluid
filler tube.
2. Place funnel in fluid filler tube.
3. Raise the vehicle.
4. Disconnect the oil cooler return line from the
transmission (rear fitting).
5. Connect one end of the hose to the oil cooler
return pipe and guide the other end so far
upwards to enable it to be hooked into the
funnel later on.
6. Lower the vehicle. Hook the free end of the
hose onto the funnel.
7. Start the engine and let it idle. The selector
lever is in NEUTRAL.
8. As soon as the fluid coming out of the hose is
no longer viscous, check the fluid. About 1/2
liter of automatic transmission fluid must flow
through in 30 seconds. If the flow is
sufficient, the test is complete.
9. If the flow is not sufficient, stop the engine.
Disconnect the hose from the oil cooler and
connect it to the output line of the converter
housing (front connection).
10. Repeat Steps 7 and 8. If adequate fluid
flow is now measured, carry out the steps
described for back flushing/cleaning in
"Cleaning and Testing"; see also "Diagnosis
of the Automatic Transmission Fluid Cooler". Item Part Description
If the fluid flow is insufficient, repair the pump Number
and/or torque converter.
1 - Out
2 - In
Transmission Fluid Cooler Tubes

Transaxle Cooler Backflushing/Cleaning

1. For rinsing, use Converter/Oil Cooler Cleaner
number 014-00028 or equivalent. Before
starting work, check the equipment to
determine whether large quantities of fluid
can flow freely/are present. If the flow is
weak, renew the filter.
2. To aid in connecting the cleaner to the
transmission steel cooler lines, connect two
additional rubber hoses to the transmission
end of the steel transmission cooler lines:
• Connect the cleaner pressure line to the oil
cooler return line (longer line).
• Connect the cleaner return line to the oil
cooler pressure line (shorter line).
3. Turn on the solvent pump and allow the
solvent to circulate a minimum of five
minutes (cycling the switch on and off will

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307-01A-55 Automatic Transmission/Transaxle — Vehicles With: 307-01A-55
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

help dislodge contaminants in the cooler
system).
4. Switch off the cleaner pump and disconnect
the cleaner pressure line from the oil cooler
return line.
5. Connect the air line hose to the oil cooler
return line. Blow compressed air through the
oil cooler and lines until all the cleaner has
been removed.
6. Disconnect the second rubber hose from the
other oil cooler line.

Fluid Cooler Tube - Remove and Install

If the oil cooler is leaking, it must be renewed.
REFER to Section 307-02A / 307-02B.
If one or more oil cooler lines have to be
renewed, each new steel tube must have the
same diameter as the line it is replacing.
Using the oil cooler line which was removed as a
template, bend the replacement line as
necessary. Attach the necessary connections
and install the oil cooler line.
After tightening the connections, fill up with
transmission fluid as necessary and check for
leaks.

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307-01A-56 Automatic Transmission/Transaxle — Vehicles With: 307-01A-56
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

Diagnosis By Symptom

the tests using the Diagnostic Tool. Never

Starting with a symptom, the mechanic is
skip tests. Carry out the necessary repairs. If
provided with diagnostic information from the
the concern is still present after electrical
Symptom Chart. In addition, the diagnosis
diagnosis, proceed to the
direction is indicated and possibly the component
hydraulic/mechanical routine listed.
causing the fault is named.
NOTE: Make sure that all the electrical
The Symptom Charts are divided into two components are working correctly before
categories: the electrical routines, indicated by proceeding to the hydraulic/mechanical routine
200 series numbers, and hydraulic/mechanical listed.
routines, indicated by 300 series numbers. In the
5. The hydraulic/mechanical routines list the
electrical routines, the electrical components are
possible hydraulic or mechanical
listed. The hydraulic/mechanical routines list the
components which could possibly cause the
hydraulic or mechanical components which could
concern described. These components are
possibly cause the symptom described.
listed in the removal sequence and by their
likelihood of being the cause. All components
listed must be inspected so that proper
Diagnosis by Symptom Chart Directions
servicing is guaranteed.
1. Consult the symptom chart table and select
the symptom/concern.
2. Move on to the diagnostic procedures given
in the symptom chart.
3. Always begin diagnosis of a symptom by
using the following:
• Preliminary inspections
• Verification of condition
• Fluid level check
• Test procedures according to details in the
table
4. If indicated, start with the electrical routine.
Follow the instructions given under
Reference/Action. If required, always perform

Symptom Chart
Hydraulic/
Title Electrical* Mechanical
Engagement Concerns
No Forward 1) 301
No Reverse 202 302
Harsh Reverse or Forward Engagement 203 303
Delayed Engagement of Forward or Reverse 1) 305
No Forward Engagement or Reverse 1) 307
Shift Concerns
Some or All Shifts Missing 210 310
Shift Timing - Early/Late 211 311
Shift Timing - Erratic/Surging 212 312
Feel - Soft/Slipping 213 313
Feel - Harsh 214 314
No 1st Gear, Engages in Higher Gear 215 315
No Manual 1st Gear 216 316
1-2 shift (automatic) 220 320

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307-01A-57 Automatic Transmission/Transaxle — Vehicles With: 307-01A-57
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Hydraulic/
Title Electrical* Mechanical
2-3 shift (automatic) 221 321
3-4 shift (automatic) 222 322
Only 1-2 shift soft/slipping (automatic) 226 326
Only 2-3 shift soft/slipping (automatic) 227 327
Only 3-4 shift soft/slipping (automatic) 228 328
Only 4-3 shift soft/slipping (automatic) 229 329
Only 3-2 shift soft/slipping (automatic) 230 330
Only 2-1 shift soft/slipping (automatic) 231 331
Only 1-2 shift abrupt (automatic) 232 332
Only 2-3 shift abrupt (automatic) 233 333
Only 3-4 shift abrupt (automatic) 234 334
Only 4-3 shift abrupt (automatic) 235 335
Only 3-2 shift abrupt (automatic) 236 336
Torque Converter Lock-Up Clutch
No Apply 240 340
Always Applied/Stalls Vehicle 241 341
Other Shift Concerns
Shift Lever Effort High 1) 351
External Leaks 1) 352
Poor Vehicle Performance 253 353
Noise/Vibration - Forward/Reverse 1) 354
Engine will Not Crank 255 355
No PARK Range 1) 356
Transmission Overheating 257 357
No Engine Braking in Manual first Position 258 358
No Engine Braking in DRIVE (O/D switch on) or Selector Lever 259 359
Position "2".
Vehicle Movement with Gear Selector in the "N" Position 1) 362
Reference: Pressure Chart 401
Reference Table: Clutch/Band Application 601
Reference Table: Solenoid Application Chart 701
Perform electrical routine first. 1) not caused by an
electrical component
Routines

ENGAGEMENT CONCERN: NO FORWARD

301 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Internal or External Shift Linkages
- Damaged, out of adjustment, incorrectly assem- Check and repair if necessary. Ensure correct ad-
bled justment of the gear shift; refer to the adjustment
procedure. After completing the repair, make sure
that the transmission range sensor (TR sensor) is
correctly adjusted.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Porosity/crossleaks and/or ball plug missing or - Check for porosity and leaks. Renew as neces-
leaking, or a plugged hole sary.

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307-01A-58 Automatic Transmission/Transaxle — Vehicles With: 307-01A-58

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

301 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Pump hub seal ring, no 3 or no 4, damaged - Check for damage and repair as necessary.
Main Control Valve Body Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gaskets damaged or leaking - Check for damage and repair as necessary.
- Pressure plate damaged or leaking - Check for damage and repair as necessary.
- Separator plates damaged - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Main regulator valve stuck, damaged or incor- - Check for damage and repair as necessary.
rectly assembled
- Forward accumulator leaking - Check for damage and repair as necessary.
Forward Clutch and Coast Clutch Assembly
- Seals or pistons damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Forward clutch return springs damaged - Check for damage and repair as necessary.
- Ball check valve damaged - Check for incorrect positioning, poor seating,
damage. Renew the piston if necessary.
- Friction plates severely damaged or worn - Check for excessive wear or damage and repair
as necessary.
- Forward/coast/direct clutch cylinder damaged, - Check for damage and repair as necessary.
leaking, incorrectly assembled or sticking
- Cylinder to hub weld broken or splines damaged - Check for damage and repair as necessary.
Clutch - Low One-Way
- Worn, damaged, incorrectly assembled - Check for damage and repair as necessary.
Forward One-Way Clutch
- Worn, damaged, incorrectly assembled - Check for damage and repair as necessary.
Low-Intermediate Carrier
- Damaged, incorrectly assembled - Check for damage and repair as necessary.

ENGAGEMENT CONCERN: NO REVERSE

202 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, solenoid valve 1 (SS1) activated, transmis- pair as necessary. Clear trouble codes, road test
sion range sensor (TR sensor) and check again using the Diagnostic Tool.

ENGAGEMENT CONCERN: NO REVERSE

302 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
External Shift Linkage
- Damaged, out of adjustment - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted.
Incorrect pressures

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307-01A-59 Automatic Transmission/Transaxle — Vehicles With: 307-01A-59
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

302 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Low line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure and perform a stall
speed test; for data refer to reference table no.
401, transmission fluid pressures. If the operating
pressure is low, check the following components
which may be the cause: Valve body, transmission
fluid pump, reverse clutch, low/reverse clutch.
Internal Shift Linkage
- Damaged, out of adjustment - Check and repair as necessary. Make sure the
gear shift is correctly adjusted; refer to Adjustment.
After completing the repair, make sure that the
transmission range sensor (TR sensor) is correctly
adjusted.
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage and repair as necessary.
- 1-2 shift valve, SS1, main regulator valve, - Check for damage and repair as necessary.
low/reverse modulator valve, low/reverse accumu-
lator piston, pressure plate damaged, missing,
stuck, incorrectly assembled
- Separator plates damaged - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- Porosity/crossleaks/ball plug missing or leaking, - Renew pump assembly.
plugged hole
- Pump hub seal rings no. 6 or no. 7 damaged - Check for damage and repair as necessary.
Clutch - Reverse
- Seals or pistons damaged - Perform Air Pressure Test.
- Ball check valve damaged - Check for damage and repair as necessary.
- Friction plates worn, severely damaged or incor- - Check for damage and repair as necessary.
rectly assembled
- Piston return spring damaged - Check for damage and repair as necessary.
- Reverse clutch hub to forward/coast/direct hub - Check for damage and repair as necessary.
splines damaged
Low/Reverse Clutch Assembly
- Seals or piston damaged - Perform Air Pressure Test.
- Friction plates worn or severely damaged - Check for damage and repair as necessary.
- Piston return spring damaged - Check for damage and repair as necessary.
- Waved washer missing - Check for damage and repair as necessary.
- Piston bore damaged - Check for damage and repair as necessary.
Forward/Coast/Direct Clutch Cylinder
- Reverse seal rings damaged, missing, incorrectly - Check for damage and repair as necessary.
assembled
Case - Perform Air Pressure Test.
- Reverse clutch supply lines at low /reverse clutch - Perform Air Pressure Test.
heavily leaking or porous.
- Check for damage and repair as necessary.
Reverse/Overdrive Gear Set

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307-01A-60 Automatic Transmission/Transaxle — Vehicles With: 307-01A-60

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

302 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Damaged - Check for damage and repair as necessary.

ENGAGEMENT CONCERN: HARSH REVERSE OR FORWARD

203 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, mainline pressure control (EPC) solenoid pair as necessary. Clear trouble codes, road test
valve, transmission fluid temperature (TFT) sensor and check again using the Diagnostic Tool.

ENGAGEMENT CONCERN: HARSH REVERSE OR FORWARD

303 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Fluid
- Level - Adjust fluid to correct level.
- Condition - Inspect; refer to Transmission Fluid Condition
Check.
CV Joints/Front axle driveshaft and Joint
- Splines damaged - Check for damage. Repair where necessary.
Powertrain bearing
- Loose, broken, missing or misaligned - Check the bearing and repair as necessary.
- Powertrain touching other vehicle components - Check for contact and resolve as necessary.
External Shift Linkage
- Damaged, out of alignment - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to the procedure for
adjustment.
Incorrect pressures
- Incorrect line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure and perform a stall
speed test; for data refer to reference table no.
401, transmission fluid pressures. If the operating
pressure is high, test the engagement at the low-
est operating pressure using the transmission test-
ing equipment. If the operating pressure remains
high, check the following components: Valve body
Internal Shift Linkages
- Damaged, out of adjustment - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to the procedure
during adjustment.
Fluid Filter and Seal Assembly
- Filter/seal damaged, plugged - Renew filter and seal assembly.
- Recirculation seal damaged, blocked or out of - Renew recirculation seal.
position

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307-01A-61 Automatic Transmission/Transaxle — Vehicles With: 307-01A-61
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

303 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage and repair as necessary.
- Low/reverse accumulator piston and spring (re- - Check for damage and repair as necessary.
verse), main regulator valve, forward accumulator
piston and spring incorrectly assembled, stuck or
damaged
- Mainline pressure solenoid (EPC) stuck or dam- - Check for damage or contamination. Operate the
aged solenoid valve using the transmission testing
equipment, repair as necessary.
Forward Clutch Assembly (Forward Only)
- Forward clutch housing damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Piston bore damaged - Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Forward clutch return spring damaged or missing - Check for damage and repair as necessary.
- Ball check damaged - Check for damage and repair as necessary.
- Piston or seal damaged - Check for damage and repair as necessary.
Reverse Clutch Assembly (Reverse Only)
- Seal or piston damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Reverse piston damaged - Check for damage and repair as necessary.
- Friction plates damaged, worn, incorrectly as- - Check for damage and repair as necessary.
sembled
- Return spring assembly damaged, worn - Check for damage and repair as necessary.
- Ball check damaged, missing - Check for damage and repair as necessary.
Low/Reverse Clutch Assembly (Reverse Only)
- Seals or reverse clutch piston damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Waved washer damaged - Check for damage and repair as necessary.
- Friction plates damaged, worn, incorrectly as- - Check for damage and repair as necessary.
sembled
- Return spring assembly damaged, worn - Check for damage and repair as necessary.
- Check ball damaged, missing - Check for damage and repair as necessary.
Direct Clutch Assembly (Reverse Only)
- Friction plates severely damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.

ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE OR FORWARD

305 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Automatic transmission fluid
- Not filled to correct level - Adjust fluid to correct level.
- Condition - Inspect; refer to Preliminary Inspection, Check
Fluid Level and Condition.
External Shift Linkages

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307-01A-62 Automatic Transmission/Transaxle — Vehicles With: 307-01A-62

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

305 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Damaged, incorrectly adjusted or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Automatic
Transmission, Assembly.
Incorrect pressures
- Low line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure and perform a stall
speed test; for data refer to reference table no.
401, transmission fluid pressures. If the operating
pressure is low, check the following components
which may be the cause: Valve body, transmission
fluid pump, clutches, transmission fluid filter and
seal, recirculation sealing ring.
Internal Shift Linkages
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Transmission,
Assembly.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Porosity/cross leaks/ball plug missing or leaking, - Renew pump assembly.
or passage blockage
- Damaged oil seals: nos. 3 or 4 (forwards) or nos. - Check for damage and repair as necessary.
6 or 7 (reverse) - oil pump hub
- Pump gear/pocket damaged - Check for damage and repair as necessary.
Damaged separator plate - Check for damage and repair as necessary.
Fluid Filter and Seal Assembly
- Filter/seal damaged, plugged - Renew filter and seal assembly.
- Recirculation seal damaged or out of position - Renew/reseat recirculation seal.
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Manual shift valve, main regulator valve, modula- - Check for damage and repair as necessary.
tor valve for low /reverse gear stuck, damaged or
incorrectly assembled
- Separator plates damaged - Check for damage and repair as necessary.
- Pressure plate/gasket leaks, damaged, incor- - Check for damage and repair as necessary.
rectly installed
Low/Reverse Clutch Assembly (Reverse Only)
- Piston or seals damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Piston bore damaged - Check for damage and repair as necessary.
- Excessive clutch pack end clearance - Check for damage and repair as necessary.
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307-01A-63 Automatic Transmission/Transaxle — Vehicles With: 307-01A-63
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

305 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Reverse Clutch Assembly (Reverse Only)
- Seals or piston damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Check ball damaged - Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Return spring worn, damaged - Check for damage and repair as necessary.
- Piston bore damaged - Check for damage and repair as necessary.
- Excessive clutch pack end clearance - Check for damage and repair as necessary.
Forward Clutch Assembly (Forward Only)
- Seals or piston damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Ball check damaged, missing or not seating cor- - Check for damage and repair as necessary.
rectly
- Friction plates damaged, worn or excessive end - Check for damage and repair as necessary.
clearance
Forward/Coast/Direct Clutch Cylinder
- Reverse seal ring damaged or missing - Check for damage and repair as necessary.
- Cylinder damaged or leaking - Check for damage and repair as necessary.

ENGAGEMENT CONCERN: NO FORWARD AND NO REVERSE

307 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Fluid
- Not filled to correct level - Adjust fluid to correct level.
External Shift Linkages
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Transmission,
Assembly.
Incorrect pressures
- Low/no line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Perform the operating pressure test and the stall
speed test. For data refer to reference table no.
401, Transmission Fluid Pressures. If the operat-
ing pressure is low, check the following compo-
nents which may be the cause: Transmission fluid
filter and gasket, valve body, transmission fluid
pump. If OK continue with the turbine shaft.
Internal Shift Linkages
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Automatic
Transmission, Assembly.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged, missing - Check for damage. Renew as necessary.

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307-01A-64 Automatic Transmission/Transaxle — Vehicles With: 307-01A-64

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

307 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Porosity/cross leaks or passage(s) blocked - Check for porosity, leaks and blockages. Renew
the pump if necessary.
- Pump hub seal ring missing - Check for damage and repair as necessary.
- Pump shaft broken, damaged - Check for damage and repair as necessary.
Fluid Filter and Seal Assembly
- Filter/seal damaged, blocked, or missing - Renew filter and seal assembly.
- Recirculation seal damaged or out of position - Renew/reseat recirculation seal.
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Pressure plate damaged or missing - Check for damage and repair as necessary.
- Main regulator valve, manual valve stuck, dam- - Check for damage and repair as necessary.
aged, plugged, missing, "Z" link not connected
Engine drive plate (starter ring gear)
- Damaged, broken - Check for damage and repair as necessary.
Torque Converter
- Pump drive shaft insert damaged - Check for damage and repair as necessary.
- Studs broken or damaged - Check for damage and repair as necessary.
- Splines damaged - Check for damage and repair as necessary.
- Internal blades damaged, broken - Check the torque converter. If damaged, renew.
Turbine Shaft to Forward/Coast/Direct Clutch Cyl-
inder Housing
- Splines damaged - Check for damage. Repair where necessary.
Chain and Sprocket Assembly
- Broken, damaged - Check for damage and repair as necessary.
Park Mechanism
- Parking pawl return spring damaged, missing in- - Check for damage and repair as necessary.
correctly installed
Front Wheel Drive Shafts and Joints
- Broken or splines damaged - Check for damage and repair as necessary.
Final Drive and Differential Assembly
- Splines damaged - Check for damage and repair as necessary.
- Gearset damaged - Check for damage and repair as necessary.
Planetary Gearset
- Gear teeth, carriers, splines damaged, or broken - Check for damage and repair as necessary.

SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING

210 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs. vehicle wiring looms, - Perform Shift Point Road Test; refer to Road Test
PCM, shift valves, transmission range sensor (TR Vehicle.
sensor), throttle position sensor (TPS), VSS, TCS
- Perform diagnosis using the Diagnostic Tool, re-
pair as necessary. Clear trouble codes, road test
and check again using the Diagnostic Tool.

SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING

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307-01A-65 Automatic Transmission/Transaxle — Vehicles With: 307-01A-65
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

310 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Fluid
Internal and External Shift Linkages - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Automatic
Transmission, Assembly.
Speedometer drive pinion - Check for damage and repair as necessary.
Go to Reference/Action to diagnose specific miss-
ing shifts

SHIFT CONCERNS: SHIFT TIMING - EARLY/LATE

211 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs. vehicle wiring looms, - Perform Shift Point Road Test; refer to Road
PCM, shift valves, transmission range sensor (TR Testing Vehicle.
sensor), throttle position sensor (TPS), VSS, TCS
- perform diagnosis using the Diagnostic Tool, re-
pair as necessary. Clear trouble codes, road test
and check again using the Diagnostic Tool.

SHIFT CONCERNS: SHIFT TIMING - EARLY/LATE

311 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Other
- Tire size change - Refer to the specification plate on the door panel
and make sure that the original vehicle equipment
is installed. A change of tire size or the speedome-
ter drive pinion affects the shift timing.
- Speedometer gear broken or otherwise incorrect - Check for damage and repair as necessary.
- Speedometer worm gear damaged - Check for damage and repair as necessary.

SHIFT CONCERNS: TIMING - ERRATIC/HUNTING

212 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Engine concerns - Refer to the specification plate on the door panel
and make sure that the original vehicle equipment
is installed. A change of try size or the speedome-
ter drive pinion affects the shift timing.
- Check for damage and repair as necessary.

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307-01A-66 Automatic Transmission/Transaxle — Vehicles With: 307-01A-66

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

212 - ELECTRICAL ROUTINE
Possible Component Reference/Action
- Electrical inputs/outputs, vehicle wiring looms, - Check for damage and repair as necessary.
PCM, shift valves, transmission range sensor (TR-
Sensor), brake on/off switch (BOO), torque con-
verter clutch solenoid valve (TCC), vehicle speed
sensor (VSS), throttle position sensor (TP), turbine
shaft speed sensor (TSS), electronic pressure
control solenoid (EPC), 3-2 shift/coast clutch sole-
noid (CCS).

SHIFT CONCERNS: TIMING - ERRATIC/HUNTING

312 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Automatic transmission fluid - Adjust fluid to correct level.
- Not filled to correct level - Adjust fluid to correct level.
- Condition - Inspect; refer to Transmission Fluid Condition
Check.
Speedometer drive pinion
- Speedometer worm gear damaged - Check for damage and repair as necessary.
- Speedometer drive pinion damaged - Check for damage and repair as necessary.
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- 3-2 timing valve, 2nd gear regulator valve, 2-4 - Check for damage and repair as necessary.
accumulator, servo release shuttle valve, 3-2 con-
trol valve stuck, damaged, incorrectly installed
- Solenoid screen blocked -Clean or renew screen.
Separator plates damaged, blocked - Check for damage and repair as necessary.
- Pressure plate/gasket damaged - Check for damage and repair as necessary.
Diagnosis of specific shift quality concerns in ac-
cordance with adjacent diagnostic procedures
- Shift Concern: No 1-2 Shift - Routine 220/320
- Shift Concern: No 2-3 Shift - Routine 221/321
- Shift Concern: No 3-4 Shift - Routine 222/322
- Shift Concern: Soft/Slip 1-2 Shift - Routine 226/326
- Shift Concern: Soft/Slip 2-3 Shift - Routine 227/327
- Shift Concern: Soft/Slip 3-4 Shift - Routine 228/328
- Shift Concern: Soft/Slip 4-3 Shift - Routine 229/329
- Shift Concern: Soft/Slip 3-2 Shift - Routine 230/330
- Shift Concern: Soft/Slip 2-1 Shift - Routine 231/331
- Shift Concern: Harsh 1-2 Shift - Routine 232/332
- Shift Concern: Harsh 2-3 Shift - Routine 233/333
- Shift Concern: Harsh 3-4 Shift - Routine 234/334
- Shift Concern: Harsh 4-3 Shift - Routine 235/335
- Shift Concern: Harsh 3-2 Shift - Routine 236/336

Feel - Soft/Slipping
213 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System

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307-01A-67 Automatic Transmission/Transaxle — Vehicles With: 307-01A-67
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

213 - ELECTRICAL ROUTINE
Possible Component Reference/Action
- Electrical inputs/outputs, vehicle wiring har- - Perform Shift Point Road Test; refer to Road
nesses, PCM, electronic pressure control solenoid Testing Vehicle.
(EPC), transmission fluid temperature (TFT) sen-
sor, throttle position sensor (TPS), MAF sensor.
- Perform diagnosis using the Diagnostic Tool, re-
pair as necessary. Clear trouble codes, road test
and check again using the Diagnostic Tool.

Feel - Soft/Slipping
313 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Automatic transmission fluid
- Not filled to correct level - Adjust fluid to correct level.
- Condition - Inspect; refer to Transmission Fluid Condition
Check.
External Shift Linkage
- Damaged, out of adjustment - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Automatic
Transmission, Assembly.
Incorrect pressures
- Low line pressure - Measure the operating pressures using a pres-
sure connection at the mainline pressure blanking
plug. Test the operating pressure; for data refer to
reference table no. 401, transmission fluid pres-
sures. If the operating pressures are low or if all
shifts are soft or slipping, check the following com-
ponents: valve body, transmission fluid pump,
transmission fluid filter/seal. If the pressures are
OK and only one particular shift is soft/slipping, re-
fer to the appropriate routine(s) for additional diag-
nosis.
- Shift 1-2, Routine 226/326
- Shift 2-3, Routine 227/327
- Shift 3-4, Routine 228/328
- Shift 4-3, Routine 229/329
- Shift 3-2, Routine 230/330
- Shift 2-1, Routine 231/331
Internal Shift Controls
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Automatic
Transmission, Assembly.
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Inspect gaskets and renew as required.

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307-01A-68 Automatic Transmission/Transaxle — Vehicles With: 307-01A-68

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

313 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Main regulator valve, system pressure modulator - Check for damage and repair as necessary.
valve stuck, damage or incorrectly installed or
springs missing, tangled or damaged
- EPC solenoid stuck or damaged - Check for damage or contamination. Operate the
solenoid valve using the transmission testing
equipment, repair as necessary.
Separator plates damaged, blocked - Check for damage and repair as necessary.
- Pressure plate/gasket damaged or missing - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage and repair as necessary.
- Porosity/cross-leaks - Check for damage and repair as necessary.
Fluid Filter/Seal Assembly
- Filter/seal damaged, blocked or missing - Renew filter and seal assembly.
- Recirculation seal damaged or out of position - Renew recirculation seal.

GEARSHIFT: ABRUPT
214 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform torque converter lock-up clutch opera-
PCM, electronic pressure control solenoid (EPC), tion test; refer to Road Test Vehicle.
transmission fluid temperature sensor (TFT),
torque converter speed sensor (TSS), throttle posi-
tion sensor (TP), vehicle speed sensor (VSS),
mass air flow sensor (MAF), torque converter lock-
up clutch solenoid (TCC), transmission range sen-
sor (TR-Sensor), 3-2 shift/coast clutch solenoid
(CCS)
- Perform diagnosis using the Diagnostic Tool, re-
pair as necessary. Clear trouble codes, road test
and check again using the Diagnostic Tool.

GEARSHIFT: ABRUPT
314 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Automatic transmission fluid
- Not filled to correct level - Adjust fluid to correct level.
- Condition - Inspect; refer to Check Fluid Level and Condition.
CV Joint/Front axle driveshaft and Joints
- Damaged, loose, splines damaged - Check for damage and repair as necessary.
Powertrain bearing
- Damaged, loose, missing - Check for damage and repair as necessary.
Incorrect pressures

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307-01A-69 Automatic Transmission/Transaxle — Vehicles With: 307-01A-69
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

314 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- High line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure and perform a stall
speed test; for data refer to reference table no.
401, transmission fluid pressures. If the operating
pressures are high or if all the shifts are harsh,
continue with the test of the valve body.
- If pressures are OK and only a specific shift is
harsh, refer to the appropriate shift routine for ad-
ditional diagnosis.
- Shift 1-2, Routine 232/332
- Shift 2-3, Routine 233/333
- Shift 3-4, Routine 234/334
- Shift 4-3, Routine 235/335
- Shift 3-2, Routine 236/336
- Shift 2-1, Routine 237/337
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage and repair as necessary.
- Main regulator valve, bypass valve or the line - Check for damage and repair as necessary.
modulator valve is sticking, damaged or incorrectly
assembled. springs caught, missing, damaged
- EPC solenoid stuck or damaged - Check for damage or contamination. Operate the
solenoid valve using the transmission testing
equipment, repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Separator plate damaged, blocked - Check for damage and repair as necessary.
Torque Converter Assembly NOTE: If the TCC is engaged during shifts:
- Piston damaged - Check for damage and repair as necessary.
- Pump hub seal No. 1 (CBY circuit) leaking, miss- - Check for damage and repair as necessary.
ing or damaged
- Case leaking - Check for damage and repair as necessary.
- Converter assembly damaged - If heat stained, renew converter.

SHIFT CONCERNS: NO 1ST GEAR, ENGAGES IN HIGHER GEAR

215 Electrical System
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, shift valve, transmission range sensor (TR pair as necessary. Clear trouble codes, road test
sensor) and check again using the Diagnostic Tool.

SHIFT CONCERNS: NO 1ST GEAR, ENGAGES IN HIGHER GEAR

315 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
External Shift Linkages

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307-01A-70 Automatic Transmission/Transaxle — Vehicles With: 307-01A-70

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

315 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Damaged, out of adjustment or incorrectly as- - Check for correct adjustment and repair as nec-
sembled essary. Ensure correct adjustment of the gear
shift; refer to the adjustment procedure. After
completing the repair, make sure that the trans-
mission range sensor (TR sensor) is correctly ad-
justed; refer to Transmission, Assembly.
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage and repair as necessary.
- 2nd gear regulator valve, solenoid regulator - Check for damage and repair as necessary.
valve, shift valves stuck, damaged, incorrectly in-
stalled
- Solenoid filter seal damaged or fitted incorrectly - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
- SS1, SS2 solenoid not functioning Operate the solenoid valve using the transmission
testing equipment, repair as necessary.
Use the transmission testing equipment for diag-
nosing a specific gear
- Refer to the following routines:
- Shift 1-2, Routine 220/320
- Shift 2-3, Routine 221/321
- Shift 3-4, Routine 222/322
Mechanical
- Seals, clutches damaged, worn - Refer to the dismantling routine, repair as neces-
sary.
- Direct clutch, 2/4 band, 2/4 servo damaged, - Refer to the dismantling routine, repair as neces-
stuck on sary.

SHIFT CONCERNS: NO MANUAL 1ST GEAR

216 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, shift valve, transmission range sensor (TR pair as necessary. Clear trouble codes, road test
sensor) and check again using the Diagnostic Tool.

SHIFT CONCERNS: NO MANUAL 1ST GEAR

316 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Internal and External Shift Linkages
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to Automatic
Transmission, Assembly.
Main Controls
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Inspect for damage, Renew as required.

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307-01A-71 Automatic Transmission/Transaxle — Vehicles With: 307-01A-71
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

316 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- 2nd gear pull-in valve stuck, damaged - Inspect for damage, Renew as required.
- SS2 stuck "on" Operate the solenoid valve using the transmission
testing equipment, repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
Separator plates damaged, blocked - Check for damage and repair as necessary.

SHIFT CONCERNS: NO 1-2 SHIFT (AUTOMATIC)

220 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, shift valve, transmission range sensor (TR pair as necessary. Clear trouble codes, road test
sensor) and check again using the Diagnostic Tool.

SHIFT CONCERNS: NO 1-2 SHIFT (AUTOMATIC)

320 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Incorrect pressures
- Line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure and perform a stall
speed test; for data refer to reference table no.
401, transmission fluid pressures. If not OK, check
the following component: Valve body
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- 1-2 shift valve, 2-4 accumulator, main regulator - Check for damage. Renew as necessary.
valve stuck, damaged, or incorrectly installed
- SS1 not functioning correctly - Check for damage. Operate the solenoid valve
using the transmission testing equipment.
- Pressure plate/gasket damaged - Check for damage. Renew as necessary.
- Separator plates damaged - Check for damage. Renew as necessary.
- Hydraulic passages damaged - Check for damage. Renew as necessary.
INT/OD Band and Servo Assembly NOTE: Also no 4th gear.
- Seals damaged, missing - Check for damage. Renew as necessary.
- Piston damaged - Check for damage. Renew as necessary.
- Band damaged - Check for damage. Renew as necessary.
- Springs damaged - Check for damage. Renew as necessary.
- Servo rod or rod bore damaged - Check for damage. Renew as necessary.
Clutch - Low One-Way
- Assembly - Check for damage. Renew as necessary.
OD/Reverse Sun Gear and Shell
- Damaged, weld broken - Check for damage. Renew as necessary.
- Lugs damaged - Check for damage. Renew as necessary.
Case

SHIFT CONCERNS: NO 2-3 SHIFT (AUTOMATIC)

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307-01A-72 Automatic Transmission/Transaxle — Vehicles With: 307-01A-72
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

221 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, shift valve, transmission range sensor (TR pair as necessary. Clear trouble codes, road test
sensor) and check again using the Diagnostic Tool.

SHIFT CONCERNS: NO 2-3 SHIFT (AUTOMATIC)

321 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Incorrect pressures
- Line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure; for data refer to refer-
ence table no. 401, transmission fluid pressures. If
not OK, check the following components: Valve
body
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage and repair as necessary.
- 2-3 shift valve (also no 4th), main regulator valve - Check for damage and repair as necessary.
stuck, damaged, incorrectly installed
- SS2 not functioning correctly (also no 4th) - Check for damage. Operate the solenoid valve
using the transmission testing equipment.
- Separator plates damaged - Check for damage and repair as necessary.
- Pressure plate/gasket leaks - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage and repair as necessary.
- Porosity/cross-leaks - Check for damage and repair as necessary.
- Pump hub seal rings nos. 4 or 5 damaged - Check for damage and repair as necessary.
Direct Clutch Assembly
- Seals or piston damaged - Perform Air Pressure Tests.
- Piston bore damaged - Check for damage and repair as necessary.
- Friction plates severely damaged, worn - Check for damage and repair as necessary.
- Ball check not seating correctly - Check for damage and repair as necessary.
Compression spring - Check for damage and repair as necessary.
- Cylinder bore/splines damaged - Check for damage and repair as necessary.
- Shell/hub damaged - Check for damage and repair as necessary.
INT/OD Servo
- Piston or piston bore damaged - Check for damage and repair as necessary.
- Rod bore or rod damaged, leaking - Check for damage and repair as necessary.
Case
- Leak in the servo apply, servo release or direct Check the casing for damage. Perform an air
clutch circuits. pressure test. Repair or renew as necessary.

SHIFT CONCERNS: NO 3-4 SHIFT (AUTOMATIC)

222 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System

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307-01A-73 Automatic Transmission/Transaxle — Vehicles With: 307-01A-73
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

222 - ELECTRICAL ROUTINE
Possible Component Reference/Action
- Electrical inputs/outputs, vehicle wiring looms, - perform diagnosis using the Diagnostic Tool, re-
PCM, shift valve, transmission range sensor (TR pair as necessary. Clear trouble codes, road test
sensor),TCS and check again using the Diagnostic Tool.

SHIFT CONCERNS: NO 3-4 SHIFT (AUTOMATIC)

322 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Incorrect pressures
- Line pressure - Measure the operating pressure using a pressure
connection at the mainline pressure blanking plug.
Test the operating pressure; for exact data refer to
reference table no. 401, transmission fluid pres-
sures. If outside the specified values, check the
valve body.
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage and repair as necessary.
- 3-4 shift valve, main regulator valve stuck, dam- - Check for damage and repair as necessary.
aged or incorrectly installed
- SS1 not functioning correctly (also no 1st) Operate the solenoid valve using the transmission
testing equipment, repair as necessary.
- Separator plates damaged or orifice blocked - Check for damage and repair as necessary.
INT/OD band and Servo Assembly NOTE: Also no 2nd gear.
- INT/OD band damaged, worn - Check for damage and repair as necessary.
- Servo rod or rod bore damaged - Check for damage and repair as necessary.
- Servo piston or cover damaged or leaking - Check for damage and repair as necessary.
- Springs damaged - Check for damage and repair as necessary.
Coast Clutch Assembly
- Seals damaged, missing - Check for damage and repair as necessary.
- Piston damaged - Check for damage and repair as necessary.
- Friction plates severely damaged, worn - Check for damage and repair as necessary.
- Check ball severely damaged - Check for damage and repair as necessary.
Forward One-Way Clutch
- Damaged - Check for damage and repair as necessary.
Case NOTE: Also no 2nd gear.
- Band anchor damaged - Check for damage. Perform Air Pressure Tests.
- Leak in the servo apply and servo release circuits - Check for damage and repair as necessary.

SHIFT CONCERNS: SOFT/SLIP 1-2 SHIFT ONLY (AUTOMATIC)

226 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool.
nesses, PCM, electronic pressure control (EPC) Perform the stall speed test, repair as necessary.
solenoid, transmission fluid temperature (TFT) Clear trouble codes, road test and check again us-
sensor ing the Diagnostic Tool.

SHIFT CONCERNS: SOFT/SLIP 1-2 SHIFT ONLY (AUTOMATIC)

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307-01A-74 Automatic Transmission/Transaxle — Vehicles With: 307-01A-74
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

326 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage and repair as necessary.
- 2-4 accumulator piston plug and seal (also soft 3- - Check for damage and repair as necessary.
4 shift), main regulator valve, line modulator valve
(also soft 3-4 shift) stuck, damaged or incorrectly
installed
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Pressure plate/gasket damaged - Check for damage and repair as necessary.
- Separator plates damaged - Check for damage and repair as necessary.
INT/OD Band and Servo Assembly
- Piston not tightened to correct torque - Check for damage and repair as necessary.
- Servo rod or rod bore damaged - Check for damage and repair as necessary.
- 2/4 brake band and/or reverse clutch drum as- - Check for damage and repair as necessary.
sembly worn, damaged or incorrectly assembled
- Springs damaged - Check for damage and repair as necessary.
- Servo cover and seal damaged - Check for damage and repair as necessary.
Forward OWC Assembly (slips in 1st)
- Not holding or damaged - Check for damage and repair as necessary.
Forward Clutch Assembly (slips in 1st) - Perform Air Pressure Test.
Damaged gaskets - Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Friction plates damaged - Check for damage and repair as necessary.
- Pump hub seals nos. 3 or 4 damaged - Check for damage and repair as necessary.
Low OWC Assembly
- Not overrunning, damaged - Check for damage and repair as necessary.
Low Reverse Clutch Assembly
- Friction plates severely damaged - Check for damage and repair as necessary.
Case
- Band anchor damaged
- Porosity/leaks in the servo apply and servo re-
lease circuits

SHIFT CONCERNS: SOFT/SLIP 2-3 SHIFT ONLY (AUTOMATIC)

227 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - perform diagnosis using the Diagnostic Tool. Per-
nesses, PCM, electronic pressure control (EPC) form the stall speed test, repair as necessary.
solenoid, transmission fluid temperature (TFT) Clear trouble codes, road test and check again us-
sensor ing the Diagnostic Tool.

SHIFT CONCERNS: SOFT/SLIP 2-3 SHIFT ONLY (AUTOMATIC)

327 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Pump hub seal rings No. 4 or No. 5 damaged - Check for damage. Renew as necessary.
Main Control Valve Body Assembly
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307-01A-75 Automatic Transmission/Transaxle — Vehicles With: 307-01A-75
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

327 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage. Renew as necessary.
- System pressure modulator valve (also soft 1-2 - Check for damage. Renew as necessary.
and 3-4 shifts), servo release shuttle valve stuck,
damaged or incorrectly installed
- Hydraulic passages damaged - Check for damage. Renew as necessary.
- Separator plates damaged - Check for damage. Renew as necessary.
- Pressure plate/gasket leaks - Check for damage. Renew as necessary.
Direct Clutch
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Seals or pistons damaged - Check for damage. Renew as necessary.
- Friction plates damaged, worn or excessive end - Check for damage. - Check the end float and re-
clearance pair as necessary.
- Check ball not seating correctly - Check for damage. Renew as necessary.
- Return spring damaged - Check for damage. Renew as necessary.
INT/OD Servo
- Piston or piston bore damaged - Check for damage. Renew as necessary.
- Servo rod or rod bore damaged - Check for damage. Renew as necessary.
Case
- Leak in the servo apply, servo release or direct Check the casing for damage. - Perform Air Pres-
clutch circuits sure Test.
Forward One-Way Clutch
- Not holding, damaged - Check for damage. Renew as necessary.

SHIFT CONCERNS: SOFT/SLIP 3-4 SHIFT ONLY (AUTOMATIC)

228 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, PCM, electronic pressure control (EPC) pair as necessary. Clear trouble codes, road test
solenoids, transmission fluid temperature (TFT) and check again using the Diagnostic Tool.
sensor

SHIFT CONCERNS: SOFT/SLIP 3-4 SHIFT ONLY (AUTOMATIC)

328 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specifications.
- Gasket leaks - Check for damage. Renew as necessary.
- System pressure modulator valve, 2-4 accumula- - Check for damage. Renew as necessary.
tor valve plug and seal (also soft 1-2 shift), stuck,
damaged or incorrectly installed
- Pressure plate/gasket leaks - Check for damage. Renew as necessary.
- Hydraulic passages damaged - Check for damage. Renew as necessary.
- Separator plates damaged or orifice blocked - Check for damage. Renew as necessary.
INT/OD Band and Servo Assembly - Check for damage. Renew as necessary.
- 2/4 brake band and/or reverse clutch drum as- - Check for damage. Renew as necessary.
sembly worn, damaged or incorrectly assembled
- Piston, seals or piston bore damaged, missing - Check for damage. Renew as necessary.

G37595 en 08/2002 2003.0 Mondeo

307-01A-76 Automatic Transmission/Transaxle — Vehicles With: 307-01A-76

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

328 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Servo cover or seal damaged Perform an, air pressure test. Check for damage
and repair as necessary.
- Servo rod or rod bore damaged - Check for damage. Renew as necessary.
- Springs damaged - Check for damage. Renew as necessary.
Clutch - Direct NOTE: Slipping may occur in 3rd gear. - Perform
Air Pressure Test.
- Seals damaged, missing - Check for damage. Renew as necessary.
- Piston damaged - Check for damage. Renew as necessary.
- Check ball damaged, missing or leaking - Check for damage. Renew as necessary.
- Return spring damaged - Check for damage. Renew as necessary.
- Friction plates damaged - Check for damage. Renew as necessary.
Case
- Band anchor damaged - Check for damage. Renew as necessary.
- Leak in the servo apply and servo release circuits - Check for damage. Perform an air pressure test,
renew as necessary.

SHIFT CONCERNS: SOFT/SLIP 4-3 SHIFT ONLY (AUTOMATIC)

229 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, PCM, electronic pressure control (EPC) pair as necessary. Clear trouble codes, road test
solenoid, vehicle speed sensor, MAF sensor, throt- and check again using the Diagnostic Tool.
tle position sensor (TPS).

SHIFT CONCERNS: SOFT/SLIP 4-3 SHIFT ONLY (AUTOMATIC)

329 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage and repair as necessary.
- Servo release shuttle valve, main regulator valve - Check for damage and repair as necessary.
stuck, damaged or incorrectly installed
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Pressure plate/gasket leaks, or damaged - Check for damage and repair as necessary.
Separator plates damaged, blocked - Check for damage and repair as necessary.
INT/OD Band and Servo Assembly
- 2/4 brake band and reverse clutch drum assem- - Check for damage and repair as necessary.
bly worn, damaged, or incorrectly assembled
- Servo return spring broken - Check for damage and repair as necessary.
- Servo rod damaged - Check for damage and repair as necessary.
- Piston seal damaged - Check for damage and repair as necessary.
Direct Clutch Assembly
- Seals damaged, missing - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Piston damaged - Check for damage and repair as necessary.
- Check ball damaged, missing or leaking - Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Friction plates damaged - Check for damage and repair as necessary.

G37595 en 08/2002 2003.0 Mondeo

307-01A-77 Automatic Transmission/Transaxle — Vehicles With: 307-01A-77
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

329 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Forward/Coast Clutch Assembly
- Seals damaged, missing - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Piston damaged - Check for damage and repair as necessary.
- Friction plates worn, damaged - Check for damage and repair as necessary.
- Check ball not functioning - Check for damage and repair as necessary.
- Forward clutch piston and return spring damaged - Check for damage and repair as necessary.
Case
- Porosity/leaks in the servo apply, servo release - Check for damage. Perform an air pressure
and direct clutch circuits compressed air test.

SHIFT CONCERNS: SOFT/SLIP 3-2 SHIFT ONLY (AUTOMATIC)

230 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, PCM, electronic pressure control (EPC) pair as necessary. Clear trouble codes, road test
solenoid, throttle position sensor (TPS), vehicle and check again using the Diagnostic Tool.
speed sensor (VSS), MAF sensor, 3-2 timing coast
clutch solenoid (CCS)

SHIFT CONCERNS: SOFT/SLIP 3-2 SHIFT ONLY (AUTOMATIC)

330 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- 3-2 timing valve, solenoid regulator valve, 3-2 - Check for damage and repair as necessary.
control valve stuck, damaged or incorrectly in-
stalled
- 3-2T/CCS solenoid not functioning correctly Operate the solenoid valve using the transmission
testing equipment, repair as necessary.
- Pressure plate/gasket leaks, or damaged - Check for damage and repair as necessary.
Separator plates damaged, blocked - Check for damage and repair as necessary.
Direct clutch
- Return spring damaged, broken - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Ball check not releasing - Check for damage and repair as necessary.
- Piston or seal damaged - Check for damage and repair as necessary.
INT/OD Band and Servo Assembly
- 2/4 band and/or reverse clutch drum assembly - Check for damage and repair as necessary.
worn, damaged or incorrectly assembled
- Servo piston damaged - Check for damage and repair as necessary.
- Servo return and cushion springs damaged, in- - Check for damage and repair as necessary.
correctly assembled
- Springs damaged, incorrectly assembled - Check for damage and repair as necessary.
- Servo rod bent, damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.

G37595 en 08/2002 2003.0 Mondeo

307-01A-78 Automatic Transmission/Transaxle — Vehicles With: 307-01A-78

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

330 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Damaged gaskets - Check for damage. Renew as necessary.
- Porosity/cross-leaks - Check for porosity and leaks. Renew the pump if
necessary.
- Pump hub seal rings nos. 4, 5, 6 damaged or in- - Check for damage and repair as necessary.
correctly installed
- Leak in the forward gear line to the direct gear - Check for damage and repair as necessary.
line
Case
- Band anchor damaged - Check for damage and repair as necessary.
- Leaks in the servo apply and servo release cir- - Check for damage. Perform an air pressure test.
cuits Repair as necessary.
- Case bore damaged (servo rod) - Check for damage and repair as necessary.

SHIFT CONCERNS: SOFT/SLIP 2-1 SHIFT ONLY (AUTOMATIC OR KICKDOWN)

231 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, PCM, electronic pressure control (EPC) pair as necessary. Clear trouble codes, road test
solenoid, transmission fluid temperature (TFT) and check again using the Diagnostic Tool.
sensor, throttle position sensor (TPS), MAF sen-
sor.

SHIFT CONCERNS: SOFT/SLIP 2-1 SHIFT ONLY (AUTOMATIC OR KICKDOWN)

331 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Pump Assembly
Damaged gaskets - Check for damage. Renew as necessary.
- Porosity/cross-leaks - check for leaks/porosity. Renew as necessary.
- Pump hub seals nos. 3 or 4 leaking, incorrectly - Check for damage and repair as necessary.
installed, damaged
Intermediate OD Servo and Band Assembly
- Servo piston damaged - Check for damage and repair as necessary.
- Servo piston return spring damaged - Check for damage and repair as necessary.
Forward Clutch Assembly - Perform Air Pressure Test.
- Piston or seals damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Friction plates damaged - Check for damage and repair as necessary.
Low OWC
- Damaged, not holding - Check for damage and repair as necessary.

SHIFT CONCERNS: HARSH 1-2 SHIFT ONLY (AUTOMATIC)

232 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System

G37595 en 08/2002 2003.0 Mondeo

307-01A-79 Automatic Transmission/Transaxle — Vehicles With: 307-01A-79
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

232 - ELECTRICAL ROUTINE
Possible Component Reference/Action
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, electronic pressure control solenoid (EPC), pair as necessary. Clear trouble codes, road test
transmission fluid temperature sensor (TFT), vehi- and check again using the Diagnostic Tool. Per-
cle speed sensor (VSS), turbine shaft speed sen- form the stall speed test.
sor (TSS), throttle position sensor (TPS), mass air
flow sensor (MAF), torque converter clutch sole-
noid (TCC), transmission range sensor (TR-
Sensor)

SHIFT CONCERNS: HARSH 1-2 SHIFT ONLY (AUTOMATIC)

332 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage. Renew as necessary.
- 2-4 accumulator valve, 3-2 control valve (also - Check for damage and repair as necessary.
harsh 3-4 shift) stuck, damaged or incorrectly in-
stalled
- Separator plates damaged - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- Pump hub seal rings, nos. 3 or 4, damaged - Check for damage and repair as necessary.
- Porosity/cross-leaks - Check for damage and repair as necessary.
INT/OD Band and Servo Assembly
- Cushion return springs damaged - Check for damage and repair as necessary.
- INT/OD band damaged, worn - Check for damage and repair as necessary.
- 2/4 brake band and/or reverse clutch drum as- - Check for damage and repair as necessary.
sembly worn, damaged or incorrectly assembled
Forward Clutch Assembly
Damaged gaskets - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Friction plates damaged - Check for damage and repair as necessary.
Case
- Band anchor area damaged - Check for damage. If damaged, renew the hous-
ing.

SHIFT CONCERNS: HARSH 2-3 SHIFT ONLY (AUTOMATIC)

233 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, electronic pressure control solenoid (EPC), pair as necessary. Clear trouble codes, road test
transmission range sensor (TR sensor), vehicle and check again using the Diagnostic Tool.
speed sensor (VSS), transmission fluid tempera-
ture sensor (TFT), mass air flow sensor (MAF),
torque converter clutch solenoid (TCC), turbine
shaft speed sensor (TSS).

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307-01A-80 Automatic Transmission/Transaxle — Vehicles With: 307-01A-80
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

SHIFT CONCERNS: HARSH 2-3 SHIFT ONLY (AUTOMATIC)

333 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage. Renew as necessary.
- System pressure modulator valve (also 1-2 and - Check for damage and repair as necessary.
3-4 harsh shift), servo release shuttle valve stuck,
damaged or incorrectly installed
- Separator plates damaged - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- Porosity/cross-leaks - Check for damage and repair as necessary.
- Pump hub seal rings nos. 4 or 5 damaged - Check for damage and repair as necessary.
Direct clutch
- Piston or piston bore damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Ball check not seating correctly - Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Clutch cylinder splines damaged - Check for damage and repair as necessary.
INT/OD Servo
- Servo piston or piston bore damaged - Check for damage and repair as necessary.
- Servo rod damaged - Check for damage and repair as necessary.
Case
- Leaks in the servo apply, servo release or direct Check the casing for damage. Perform an air
clutch circuits pressure test. Repair or renew the housing as
necessary.
- Servo rod bore damaged - Check for damage and repair as necessary.

SHIFT CONCERNS: HARSH 3-4 SHIFT ONLY (AUTOMATIC)

234 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, electronic pressure control solenoid (EPC), pair as necessary. Clear trouble codes, road test
vehicle speed sensor (VSS),3-2 shift/coast clutch and check again using the Diagnostic Tool.
solenoid (CCS), transmission range sensor (TR-
Sensor), transmission fluid temperature sensor
(TFT), turbine shaft speed sensor (TSS), throttle
position sensor (TPS), mass air flow sensor
(MAF), torque converter clutch solenoid (TCC)

SHIFT CONCERNS: HARSH 3-4 SHIFT ONLY (AUTOMATIC)

334 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage. Renew as necessary.

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307-01A-81 Automatic Transmission/Transaxle — Vehicles With: 307-01A-81
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

334 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- System pressure modulator valve (also 1-2 and - Check for damage and repair as necessary.
2-3 harsh shift), 3-2 control valve, 2-4 accumulator
valve, coast clutch valve, stuck, damaged or incor-
rectly installed
- Hydraulic passages damaged - Check for damage and repair as necessary.
Separator plates damaged, blocked - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Porosity/cross-leaks - Check for damage and repair as necessary.
- Coast clutch Teflon seals damaged - Check for damage. Renew as necessary.
INT/OD Band and Servo Assembly
- 2/4 band and reverse clutch drum assembly, - Check for damage and repair as necessary.
damaged, worn, incorrectly assembled
- Servo piston or cover damaged or leaking - Check for damage and repair as necessary.
- Springs damaged - Check for damage and repair as necessary.
Coast Clutch Assembly
- Piston or seals damaged, missing - Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Check ball not functioning - Check for damage and repair as necessary.
Direct Clutch Assembly
- Piston or seals damaged, missing - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Check ball damaged, missing or leaking - Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Friction plates damaged - Check for damage and repair as necessary.
- Clutch cylinder splines damaged - Check for damage and repair as necessary.
Case
- Band anchor damaged - Check for damage and repair as necessary.

SHIFT CONCERNS: HARSH 4-3 SHIFT ONLY (AUTOMATIC)

235 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, electronic pressure control solenoid (EPC), pair as necessary. Clear trouble codes, road test
transmission range sensor (TR-Sensor), vehicle and check again using the Diagnostic Tool.
speed sensor (VSS),3-2 shift/coast clutch solenoid
(CCS), transmission fluid temperature sensor
(TFT), turbine shaft speed sensor (TSS), throttle
position sensor (TPS), mass air flow sensor
(MAF), torque converter clutch solenoid (TCC)

SHIFT CONCERNS: HARSH 4-3 SHIFT ONLY (AUTOMATIC)

335 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket leaks - Check for damage. Renew as necessary.

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307-01A-82 Automatic Transmission/Transaxle — Vehicles With: 307-01A-82

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

335 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Servo release shuttle valve, 3-2 timing/coast - Check for damage and repair as necessary.
valve stuck, damaged or incorrectly installed
- Hydraulic passages damaged - Check for damage and repair as necessary.
Separator plates damaged, blocked - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque -Tighten bolts to specification.
- Porosity/cross-leaks, seal rings damaged, miss- - Check for damage. Renew the pump if neces-
ing or leaking ball plug sary.
- Gasket damaged - Check for damage. Renew as necessary.
- Seal rings nos. 2, 3, 4 or 5 (coast and direct - Check for damage and repair as necessary.
clutch circuits)
- Pump hub damaged - Check for damage and repair as necessary.
INT/OD Band and Servo Assembly
- Servo rod bent, damaged - Check for damage and repair as necessary.
- Servo return spring broken - Check for damage and repair as necessary.
Coast Clutch Assembly
- Seals damaged, missing - Check for damage. Repair where necessary.
- Piston damaged - Check for damage. Repair where necessary.
- Friction plates worn, damaged - Check for damage. Repair where necessary.
- Check ball not functioning - Check for damage. Repair where necessary.
- Forward clutch piston and return spring damaged - Check for damage. Repair where necessary.
Case
- Porosity/leaks in the servo apply, servo release - Check for damage. Perform an air pressure test.
and direct clutch circuits. Repair as necessary.

SHIFT CONCERNS: HARSH 3-2 SHIFT ONLY (AUTOMATIC)

236 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, electronic pressure control solenoid (EPC), pair as necessary. Clear trouble codes, road test
transmission range sensor (TR-Sensor), vehicle and check again using the Diagnostic Tool.
speed sensor (VSS),3-2 shift/coast clutch solenoid
(CCS), transmission fluid temperature sensor
(TFT), turbine shaft speed sensor (TSS), throttle
position sensor (TPS), mass air flow sensor
(MAF), torque converter clutch solenoid (TCC)

SHIFT CONCERNS: HARSH 3-2 SHIFT ONLY (AUTOMATIC)

336 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- 3-2 timing valve, solenoid regulator valve, 3-2 - Check for damage and repair as necessary.
control valve stuck, damaged, incorrectly installed
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Separator plates damaged or blocked - Check for damage and repair as necessary.

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307-01A-83 Automatic Transmission/Transaxle — Vehicles With: 307-01A-83
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

336 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- 3-2T/CCS solenoid not functioning correctly Operate the solenoid valve using the transmission
testing equipment. If the coast clutch operation is
OK, continue diagnosis on the direct clutch.
Direct Clutch Assembly
- Return spring damaged, broken - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Friction plates damaged, worn - Check for damage and repair as necessary.
- Check ball not opening - Check for damage and repair as necessary.
INT/OD Band and Servo Assembly
- INT/OD band and/or reverse clutch drum assem- - Check for damage and repair as necessary.
bly damaged, worn or incorrectly assembled
- Servo piston damaged - Check for damage and repair as necessary.
- Servo return and cushion springs damaged, in- - Check for damage and repair as necessary.
correctly assembled
- Springs damaged, incorrectly assembled - Check for damage and repair as necessary.
- Servo rod bent or damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Porosity/cross-leaks - Check for porosity and leaks. Renew as neces-
sary.
- Pump hub seal rings damaged or incorrectly in- - Check for damage and repair as necessary.
stalled
Case
- Band anchor damaged - Check for damage and repair as necessary.
- Servo rod bore damaged - Check for damage and repair as necessary.

TORQUE CONVERTER OPERATION CONCERNS: NO APPLY

240 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform torque converter clutch operation test;
nesses, PCM, transmission fluid temperature refer to Road Test Vehicle. - Perform diagnosis
(TFT) sensor, torque converter clutch (TCC) sole- using the Diagnostic Tool, repair as necessary.
noid, brake on/off (BOO) switch, turbine shaft Clear trouble codes, road test and check again us-
speed (TSS) sensor. ing the Diagnostic Tool.

TORQUE CONVERTER OPERATION CONCERNS: NO APPLY

340 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- Solenoid pressure regulator valve, bypass clutch - Check for damage and repair as necessary.
control valve and plunger, converter regulator
valve stuck, damaged, incorrectly installed
- TCC solenoid not functioning correctly Operate the solenoid valve using the transmission
testing equipment, repair as necessary.
- Hydraulic passages damaged - Check for damage. Renew as necessary.
- Separator plates damaged or blocked - Check for damage and repair as necessary.

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307-01A-84 Automatic Transmission/Transaxle — Vehicles With: 307-01A-84

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

340 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Torque Converter
- Leakage, internal damage - Check for damage and leaks. - Perform torque
converter clutch operation test; refer to Road Test
Vehicle. Renew as necessary.

TORQUE CONVERTER OPERATION CONCERN: ALWAYS APPLIED/STALLS VEHICLE

241 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform torque converter clutch operation test;
nesses, powertrain control module (PCM), trans- refer to Road Test Vehicle. - Perform diagnosis
mission fluid temperature (TFT) sensor, TCC sole- using the Diagnostic Tool, repair as necessary.
noid Clear trouble codes, road test and check again us-
ing the Diagnostic Tool.

TORQUE CONVERTER OPERATION CONCERN: ALWAYS APPLIED/STALLS VEHICLE

341 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Gasket damaged - Check for damage. Renew as necessary.
- Bypass clutch control valve and plunger (always - Check for damage and repair as necessary.
applied), converter regulator valve stuck, dam-
aged, incorrectly installed
Separator plates damaged, blocked - Check for damage and repair as necessary.
- TCC solenoid not functioning correctly. NOTE: Operate the solenoid valve using the transmission
Converter clutch not applied in 1st gear or reverse testing equipment, repair as necessary.
gear
- Pressure plate/gasket damaged - Check for damage and repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
Pump Assembly
- Bolts not tightened to correct torque - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Pump hub No. 1 seal ring damaged, missing, in- - Check for damage and repair as necessary.
correctly installed
Torque Converter Assembly
- Internal seals damaged - Check for damage and repair as necessary.
- Piston plate damaged/stuck to cover - If cover is heat stained, renew torque converter.
Case
- Porosity/cross-leaks from the clutch bypass cir- - Check for leaks/porosity, repair or renew as nec-
cuit essary.

OTHER CONCERNS: SHIFT LEVER EFFORT IS HIGH

351 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Brake Shift Interlock - Refer to diagnostic procedure.

Internal and External Shift Linkages

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307-01A-85 Automatic Transmission/Transaxle — Vehicles With: 307-01A-85
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

351 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to the procedure
during adjustment.
- Manual selector lever damaged, park inhibitor - Check for damage and repair as necessary.
mechanism damaged, shaft bent, detent lever
shaft bore (in case) damaged, detent spring
bent/damaged, nut loose
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Manual valve stuck, damaged - Check for damage and repair as necessary.

OTHER CONCERNS: EXTERNAL LEAKS

352 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Fluid
- Not filled to correct level - Adjust fluid to correct level.
Seals/Gaskets
- Differential seals, speedometer drive pinion, re- - Locate the leak, repair as necessary. If the leak
tainer seal, pump assembly, main control cover, is at the differential seal or impeller hub, check the
servo cover, split flange gasket, converter impeller return holes in the housing/converter housing,
hub, selector lever shaft seal, fluid level indicator check the surface of the linkshaft or front axle
tube driveshaft and joint for roughness. Surface rough-
ness can lead to seal failure, repair as necessary.
Other
- Fluid tube bracket, mainline pressure plug, pres- - Locate the leak, repair as necessary.
sure port plugs, drain plug, cooler tubes, case po-
rosity, cracked case
Check vent for damage or blockage, repair as re-
quired.
- Check for leaks and repair as necessary.
Sensors/Connectors
- Transmission multiplug, transmission range sen- - Locate the leak, repair as necessary.
sor (TR sensor). Turbine shaft speed sensor (TSS)
or seal

OTHER CONCERNS: POOR VEHICLE PERFORMANCE

253 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Base engine concerns - Refer to diagnostic procedure in the Workshop
Manual.
- Electrical inputs/outputs, vehicle wiring looms, - Perform torque converter clutch operation test;
PCM, transmission fluid temperature (TFT), torque refer to Road Test Vehicle. - perform diagnosis us-
converter clutch (TCC) solenoid, transmission ing the Diagnostic Tool, repair as necessary. Clear
range sensor (TR-Sensor), throttle position sensor trouble codes, road test and check again using the
(TPS) Diagnostic Tool.

OTHER CONCERNS: POOR VEHICLE PERFORMANCE

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307-01A-86 Automatic Transmission/Transaxle — Vehicles With: 307-01A-86
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

353 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Internal or external shift components or transmis-
sion range (TR sensor)
- Damaged, out of adjustment or misassembly - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to the procedure
during adjustment.
- Verify Proper Shift Timing and Engagements
- Go to the appropriate diagnostic routines in the
index
Torque Converter Clutch Always Applied - Go to Routine 341.
Torque Converter One-Way Clutch
- Damaged - Check the torque converter, repair or renew as
necessary.

OTHER CONCERNS: NOISE/VIBRATION - FORWARD/REVERSE

354 - HYDRAULIC/MECHANICAL ROUTINES
Possible Component Reference/Action
For Noises/Vibrations That Change With Engine
Speed:
- Torque converter components - Locate the source, repair as necessary.
- Fluid level (low) pump cavitation
Pump Assembly
- Engine drive accessories
- Cooler tubes touching
- Flywheel
- Inspection cover
For Noises/Vibrations that Change with Vehicle
Speed:
- Powertrain mounts loose, damaged - Locate the source, repair as necessary. For spe-
cific shifts or torque converter concerns, refer to
the routines in the index.
- Tires
- Driveline concerns: front axle driveshaft and joint
or linkshaft, differential: chain drive, suspension,
non-standard modifications
- Planetary gear sets
- Chain touching the chain cover - Inspect the chain cover for signs of damage or
incorrect installation, repair as necessary.
Forward One-Way Clutch
Torque Converter
- LH and RH front axle driveshaft and joint splines - Check for damage and repair as necessary.
worn, damaged
- Front axle driveshafts or speedometer gears
Other Noises/Vibrations:
- Shift cable and bracket vibration, touching - Locate the source, repair as necessary.
- Cooler lines touching bodywork

OTHER CONCERNS: ENGINE WILL NOT CRANK

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307-01A-87 Automatic Transmission/Transaxle — Vehicles With: 307-01A-87
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

255 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Base engine concerns - Refer to diagnostic procedure in the Workshop
Manual.
- Electrical inputs/outputs, vehicle wiring looms, - Perform diagnosis using the Diagnostic Tool, re-
PCM, shift valves, transmission range sensor (TR pair as necessary. Clear trouble codes, road test
sensor) damaged, incorrectly adjusted. and check again using the Diagnostic Tool.

OTHER CONCERNS: ENGINE WILL NOT CRANK

355 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Starter/Flywheel
- Damaged or incorrectly installed - Check for damage, incorrect installation, repair
as necessary.
Internal or external shift components or transmis-
sion range (TR sensor)
- Damaged, out of adjustment or misassembly Ensure correct adjustment of the gear shift; refer
to the adjustment procedure. After completing the
repair, make sure that the transmission range sen-
sor (TR sensor) is correctly adjusted; refer to the
procedure during adjustment.

OTHER CONCERNS: NO PARK RANGE

356 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Internal or External Shift Linkages
- Damaged, out of adjustment or misassembly - Check and repair as necessary. Ensure correct
adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted. Refer to the procedure
during adjustment.
Park Mechanism - Check for damage and repair as necessary.
- Parking lock gear on the driven sprocket, parking - Check for damage and repair as necessary.
pawl return spring, engagement springs
- Parking pawl, parking pawl shaft, selector lever, - Check for damage and repair as necessary.
cam plate drive dog, selector lever linkage spring,
transmission range sensor (TR-Sensor), parking
pawl drive plate, selector lever shaft nut damaged,
missing or incorrectly fitted

OTHER CONCERNS: TRANSAXLE OVERHEATING

257 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, PCM, torque converter clutch (TCC) sole- pair as necessary. Clear trouble codes, road test
noid, transmission fluid temperature (TFT) sensor, and check again using the Diagnostic Tool.
turbine shaft speed (TSS) sensor

OTHER CONCERNS: TRANSAXLE OVERHEATING

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307-01A-88 Automatic Transmission/Transaxle — Vehicles With: 307-01A-88
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

357 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Vehicle Concerns Causing Engine Overheating - Refer to diagnostic procedure.
Fluid
- Not filled to correct level - Adjust to correct level.
- Condition - Inspect; refer to Check Fluid Level and Condition.
If the fluid is foaming, check the thermovalve and
filter seals and repair as necessary.
Cooler Tubes
- Damaged, blocked, reversed - Check for damage and repair as necessary.
Intake Cooler
- Damaged, blocked, restricted or leaking - Check for damage and repair as necessary.
Auxiliary Cooler (if equipped)
- Damaged, blocked, restricted or leaking - Check for damage or incorrect installation, repair
as necessary.
Main Control
- Bolts not tightened to correct torque - Tighten bolts to specification.
- Main regulator valve, bypass clutch control valve, - Check for damage and repair as necessary.
converter regulator valve stuck, damaged, incor-
rectly installed
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Separator plates/gaskets damaged - Check for damage and repair as necessary.
- TCC solenoid not functioning correctly (off) Operate the solenoid valve using the transmission
testing equipment, repair as necessary.
Torque Converter Clutch - No Apply - Go to Routine 240/340
Pump Assembly
- Gasket damaged - Check for damage and repair as necessary.
- Rear lube passage blocked - Check for damage and repair as necessary.
Chain Pan
- Missing - Check whether present. If missing, install.
Thermostatic Fluid Level Control Valve
- Stuck open or damaged - Check for damage and repair as necessary.
- Gasket damaged or missing - Check for damage. Renew as necessary.
- Bolt or bracket damaged, missing, or incorrectly - Check for damage and repair as necessary.
installed
Case/Converter Housing/Stator Support
- Front lube passage blocked or restricted - Check passages, refer to Air Pressure Tests and
Air Pressure Test Port Locations for identification
of passages, repair as necessary.
- Torque converter lock-up clutch, timing passages
blocked or restricted

OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 1ST POSITION

258 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, powertrain control module, 3-2 tim- pair as necessary. Clear trouble codes, road test
ing/coast clutch solenoid and check again using the Diagnostic Tool. Per-
form the stall speed test.

OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 1ST POSITION

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307-01A-89 Automatic Transmission/Transaxle — Vehicles With: 307-01A-89
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

358 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Main Controls
- Bolts out of specification - Tighten bolts to specification.
Damaged gaskets - Check for damage. Renew as necessary.
- Low/reverse modulator valve, coast clutch valve - Check for damage and repair as necessary.
stuck, damaged or incorrectly installed
- 3-2 timing/coast clutch solenoid stuck or dam- - Check for damage or contamination. Operate the
aged solenoid valve using the transmission testing
equipment, repair as necessary.
- Hydraulic passages damaged - Check for damage and repair as necessary.
- Pressure plate/gasket damaged - Check for damage and repair as necessary.
- Separator plate/gasket damaged - Check for damage and repair as necessary.
Coast Clutch
- Incorrectly assembled, damaged - Check for damage and repair as necessary.
- Forward clutch hub seal damaged - Check for damage and repair as necessary.
- Piston or seals damaged - Check for damage and repair as necessary.
- Ball check damaged, missing - Check for damage and repair as necessary.
Low/reverse clutch
- Incorrectly assembled, damaged - Perform Air Pressure Test.
- Check for damage and repair as necessary.
- Piston or seals damaged - Check for damage and repair as necessary.
Pump Assembly
- Pump hub seals number 2 or 3 for coast clutch - Check for damage and repair as necessary.
circuit damaged, missing

OTHER GEARSHIFT DIFFICULTIES: NO ENGINE BRAKING IN DRIVE (O/D SWITCH ON) OR

SELECTOR LEVER POSITION "2".
259 - ELECTRICAL ROUTINE
Possible Component Reference/Action
Powertrain Control System
- Electrical inputs/outputs, vehicle wiring har- - Perform diagnosis using the Diagnostic Tool, re-
nesses, powertrain control module, 3-2 tim- pair as necessary. Clear trouble codes, road test
ing/coast clutch solenoid and check again using the Diagnostic Tool. Per-
form the stall speed test.

OTHER GEARSHIFT DIFFICULTIES: NO ENGINE BRAKING IN DRIVE (O/D SWITCH ON) OR

SELECTOR LEVER POSITION "2".
359 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Internal or External Shift Linkages
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to the procedure
during adjustment.
Main Controls
- 3-4 shift valve, 1-2 shift valve, 2nd gear control - Check for damage and repair as necessary.
valve, coast clutch solenoid sticking or damaged

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307-01A-90 Automatic Transmission/Transaxle — Vehicles With: 307-01A-90

4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

359 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
- 3-2 timing/coast clutch solenoid stuck or dam- - Check for damage or contamination. Operate the
aged solenoid valve using the transmission testing
equipment, repair as necessary.
Forward One-Way Clutch
- Damaged, incorrectly assembled - Check for damage and repair as necessary.
Coast clutch
- Incorrectly assembled - Check for damage and repair as necessary.
- Forward clutch hub seal assembled - Check for damage and repair as necessary.
- Piston or seals damaged - Check for damage and repair as necessary.
- Ball check damaged, missing - Check for damage and repair as necessary.
Pump Assembly
- Pump hub seals number 2 and 3 for the coast - Check for damage and repair as necessary.
clutch circuit damaged, missing

OTHER CONCERNS: VEHICLE MOVEMENT WITH GEAR SELECTOR IN THE "N" POSITION
362 - HYDRAULIC/MECHANICAL ROUTINE
Possible Component Reference/Action
Internal or External Shift Linkages
- Damaged, out of adjustment or incorrectly as- - Check and repair as necessary. Ensure correct
sembled adjustment of the gear shift; refer to the adjust-
ment procedure. After completing the repair, make
sure that the transmission range sensor (TR sen-
sor) is correctly adjusted; refer to the procedure
during adjustment.
Pump Assembly
- Gaskets severely damaged - Check for damage. Renew as necessary.
- Pump hub seal number 2, leak in the forward - Check for damage and repair as necessary.
clutch circuit
Forward/Coast Clutch Assembly
- Friction plates severely damaged - Check for damage and repair as necessary.
- Return spring damaged - Check for damage and repair as necessary.
- Check ball damaged, missing - Check for damage and repair as necessary.

CAUTION: The transmission testing

equipment must be removed from the
transmission and the vehicle wiring
harness re-connected to determine these
pressures

Reference: Pressure Chart

Shift lever position Idle (bar) Stall (bar)
PARK, NEUTRAL 4,4 - 5,2 -
REVERSE 4,4 - 5,2 18 - 20
DRIVE 3,1 - 4,3 11,6 - 12,7
SECOND 3,1 - 4,3 11,6 - 12,7
FIRST 3,1 - 4,3 11,6 - 12,7

Reference Table: Clutch/Band Application

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307-01A-91 Automatic Transmission/Transaxle — Vehicles With: 307-01A-91
4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

2/4
Inter-
mediate
Over-
drive Forward Direct Coast Low/Rev Reverse Forward One- Clutch - Low
Gear Band Clutch Clutch Clutch Clutch Clutch Way Clutch One-Way
Gear Drive Coast Drive Coast
R X X
D-1 X X OR X OR
D-2 X X X OR OR OR
D-3 X X X OR OR OR
D-4 X X X OR OR OR OR
M-2 X X X X OR OR
M-1 X X X X X
X - Transmits torque. OR - Overrunning

SOLENOID OPERATION CHART - CD4E

Transaxle Range PCM Commanded
Selector Lever Position Gear SSA SSB 3-2T/CCS TCC
P PARK OFF ON ON OFF
R REVERSE OFF ON/OFF ON *
N NEUTRAL OFF ON ON OFF
OD
D 1 ON ON ON *
D 2 OFF ON ON **
D 3 OFF OFF ON **
D 4 ON OFF ON **
OD OFF
D 1 ON ON ON *
D 2 OFF ON OFF **
D 3 OFF OFF OFF **
2 2 OFF ON OFF **
2*** 3 OFF OFF OFF **
1 1 ON ON OFF *
1*** 2 OFF ON OFF **
1*** 3 OFF OFF OFF **
*Not allowed by hydraulics.**Powertrain control
module (PCM) commanded.***When a manual pull - in
occurs above a calibrated speed, the transaxle will not
downshift from the higher gear until the vehicle speed
drops below this calibrated speed.

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307-01A-92 Automatic Transmission/Transaxle — Vehicles With: 307-01A-92
4-Speed Automatic Transaxle

GENERAL PROCEDURES
Transmission Fluid Cooler - Backflushing and Cleaning
GENERAL PROCEDURES

1. CAUTION: Do not use automatic

transmission fluid of any other
specification as this may severly
damage the automatic transmission.
NOTE: Install new gaskets, oil seals and self-
locking nuts.
Remove the fluid cooler tubes. For
additional information, refer to Section
307-02A / 307-02B.
2. CAUTION: If the automatic
transmission fluid is very dirty or it
contains metallic particles, then install
new fluid cooler tubes and a new fluid
cooler.
Using compressed air, evacuate the fluid
cooler tubes.
3. Remove the fluid cooler. For additional
information, refer to Section 307-02A / 307-
02B.
4. CAUTION: If the automatic
transmission fluid is very dirty or it
contains metallic particles, then install
new fluid cooler tubes and a new fluid
cooler.
Using compressed air, evacuate the fluid
cooler.
5. Install the fluid cooler. For additional
information, refer to Section 307-02A / 307-
02B.

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307-01A-93 Automatic Transmission/Transaxle — Vehicles With: 307-01A-93
4-Speed Automatic Transaxle

GENERAL PROCEDURES
Transmission Fluid Drain and Refill

5. Lower the vehicle

Name Specification 6. Add automatic transmission fluid into the
filler neck. For additional information,
Pipe Sealant with Tef- WSK-M2G350-A2, refer to Specifications in this section.
lon ESR-M18PZ-A
7. Check the transmission fluid level. For
Automatic transmission ESP-M2C166-H additional information, refer to Preliminary
fluid Inspection in this section.
1. Raise and support the vehicle. For 8. Add automatic transmission fluid if
additional information, refer to Section necessary.
100-02.
2. Place a suitable container under the
transaxle drain plug.
3. NOTE: If an integral problem is suspected,
drain the fluid through a paper filter. A small
amount of metal or friction particles may be
found from normal wear. However, if
excessive metal and friction particles are
present, internal service will be required.
Remove the transaxle drain plug and drain
transmission fluid.

4. Install the transaxle drain plug.

• After the fluid has been drained, clean the
drain plug threads and apply a small
amount of Pipe Sealant with Teflon .

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307-01A-94 Automatic Transmission/Transaxle — Vehicles With: 307-01A-94
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter
IN-VEHICLE REPAIR

6. CAUTION: Using and open-end

spanner, prevent the fluid pipe
Name Specification adapter from turning, do not remove
the adapter from the transaxle
Automatic transmission ESP-M2C166-H housing.
fluid
Disconnect the transaxle cooler inlet pipe.
• Allow the oil to drain into a suitable con-
Removal tainer.

1. Disconnect the battery ground cable. For

additional information, refer to Section
414-01.
2. Remove the battery tray. For additional
information, refer to Section 414-01.
3. Disconnect the solenoid body electrical
connector.

4. Disconnect the transmission range (TR)

sensor electrical connector.

5. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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307-01A-95 Automatic Transmission/Transaxle — Vehicles With: 307-01A-95
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

7. NOTE: Remove the bolts in the sequence Installation
shown.
1. Install a new fluid pan cover gasket..
Remove the fluid pan.
• Disconnect the fluid pan vent tube.

2. Install the fluid pan.

1. Connect the fluid pan vent tube.
2. Tighten the bolts in the sequence shown.

8. Remove the fluid pan cover gasket.

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307-01A-96 Automatic Transmission/Transaxle — Vehicles With: 307-01A-96

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

3. Connect the transaxle cooler inlet line. 9. Check the transmission fluid level. For
additional information, refer to Preliminary
Inspection in this section.
10. Initialize the door window motors. For
additional information, refer to Section
501-11.

4. Lower the vehicle.

5. Connect the TR sensor electrical connec-
tor.

6. Connect the solenoid body electrical con-

nector.

7. Install the battery tray. For additional

information, refer to Section 414-01.
8. Connect the battery ground cable. For
additional information, refer to Section
414-01.

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307-01A-97 Automatic Transmission/Transaxle — Vehicles With: 307-01A-97
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Main Controls
4. Remove the transmission range (TR)
sensor.
Special Tool(s) 1. Disconnect the TR sensor electrical
connector.
Aligner, Selector Shaft 2. Remove the bolts.
307-S290 (17-066)

Alignment Gauge, TR Sensor

307-351

Name Specification
Automatic transmission fluid ESP-M2C166-H
5. Remove the wiring harness retaining clip.
Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the battery tray. For additional
information, refer to Section 414-01.
3. Disconnect the solenoid body electrical
connecter.

6. Disconnect the selector lever cable and

bracket.
1. Remove the bracket retaining bolts.
2. Detach the selector lever cable from the
bracket.

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307-01A-98 Automatic Transmission/Transaxle — Vehicles With: 307-01A-98

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

9. NOTE: Remove the bolts in the sequence
7. Raise and support the vehicle. For
shown.
additional information, refer to Section
100-02. Remove the main control valve cover.
• Disconnect the main control valve cover
8. CAUTION: Prevent the fluid pipe from vent tube.
turning, use an open-end spanner, do
not remove it from the transaxle
housing.
Disconnect the transaxle cooler inlet pipe.
• Allow the oil to drain into a suitable con-
tainer.

10. Remove the main control valve cover

gasket.

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307-01A-99 Automatic Transmission/Transaxle — Vehicles With: 307-01A-99
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

11. Remove the solenoid body wiring har-

ness clip from the main control valve 14. CAUTION: Do not pull solenoid body
body. electrical connector wires.
Remove the solenoid body electrical
connector.
• Depress the retaining tabs and push the
connector through the transaxle case.

12. Remove the main control valve body re-

taining bolts.

15. CAUTION: Make sure the manual

valve control lever does not fall out.
Remove the manual valve control body.

13. CAUTION: Do not allow loose manual

valve to become damaged.
Disconnect the manual valve link from
the manual control valve when removing
the main control valve body from the
case.

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307-01A-100 Automatic Transmission/Transaxle — Vehicles With: 307-01A-100

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

Installation
4. Position the main control valve body and
1. Install the manual valve control body. install the retaining bolts in the sequence
shown.

2. NOTE: Inspect the solenoid valve body

harness connector O-ring seal and install a
new as necessary, before installing solenoid
valve body harness connector in transaxle
case.
Push the solenoid valve body harness
connector into the transaxle case.

5. Loosen the manual valve detent lever to

actuating rod assembly retaining nut.

3. Connect the manual valve link to the man-

ual valve.

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307-01A-101 Automatic Transmission/Transaxle — Vehicles With: 307-01A-101
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

6. Using the special tool and pin, align the 9. Tighten the lever to manual valve detent
shifter shaft. actuating rod assembly retaining nut.
• Rotate back to the "D" position and check
the adjustment.

7. Move the manual valve detent lever as-

sembly to the "D" position.
10. Using the special tool, check the manual
control lever assembly settings.

8. NOTE: Do not fully tighten the nut at this

stage.
Tighten the nut on the ball. 11. Install the manual control lever.
• Remove the special tool. 1. Align the manual control lever.
2. Tighten the retaining bolt.

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307-01A-102 Automatic Transmission/Transaxle — Vehicles With: 307-01A-102

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

12. Install solenoid body wiring harness clip 14. Install the main control valve cover.
to main control valve body. • Connect the main control valve cover vent
tube.
• Position main control valve cover and
tighten the bolts in the sequence shown.

13. Install a new main control valve cover

gasket.

15. Connect the transaxle cooler inlet line.

16. Lower the vehicle.

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307-01A-103 Automatic Transmission/Transaxle — Vehicles With: 307-01A-103
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

17. NOTE: Do not tighten the TR sensor bolts at 19. Adjust the TR sensor. For additional
this stage. information, refer to Transmission Range
(TR) Sensor in this section.
Install the TR sensor.
1. Install the special tool and align TR sensor
to the slots.
2. Tighten the retaining bolts.

18. NOTE: Make sure the manual control lever is

in "N" position for TR sensor adjustment.
Rotate the manual valve detent lever
assembly to the Neutral position. 20. Connect the selector lever cable to the
control lever.
1. Low 1
1. Attach the selector lever cable.
2. Low 2
2. Install the retaining bolts.
3. Drive
4. Neutral
5. Reverse
6. Park

21. Install the wiring harness retaining clip.

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307-01A-104 Automatic Transmission/Transaxle — Vehicles With: 307-01A-104

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

22. Connect the TR sensor electrical connec-
tor.

23. Connect the solenoid body electrical

connector.

24. Install the battery tray. For additional

information, refer to Section 414-01.
25. Connect the battery ground cable. For
additional information, refer to Section
414-01.
26. Check the transmission fluid level. For
additional information, refer to
Preliminary Inspection in this section.

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307-01A-105 Automatic Transmission/Transaxle — Vehicles With: 307-01A-105
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Turbine Shaft Speed (TSS) Sensor

Installation
Name Specification
1. NOTE: Install a new TSS sensor O-ring seal.
Automatic transmission fluid ESP-M2C166-H
Install the TSS sensor.
Petroleum jelly SM-1C115-A • Lubricate the O-ring seal with petroleum
jelly.
Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Disconnect the turbine shaft speed (TSS)
sensor electrical connector (colored
white).

2. Connect the TSS sensor electrical connec-

tor (colored white).

3. Remove the TSS sensor.

• Allow the oil to drain into a suitable
container.
• Discard the O-ring seal.

3. Lower vehicle.
4. Start the engine and move the selector
lever through all of the ranges, allowing
sufficient time for each position to engage.
• Engage the selector lever in the "P" (park)
position.
5. Check the transmission fluid level. For
additional information, refer to Preliminary
Inspection in this section.
6. Add automatic transmission fluid, if
necessary.

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307-01A-106 Automatic Transmission/Transaxle — Vehicles With: 307-01A-106
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor

Installation
Name Specification
1. NOTE: Install a new OSS sensor O-ring seal.
Automatic transmission fluid ESP-M2C166-H
Install the OSS sensor.
Petroleum jelly SM-1C115-A • Lubricate the O-ring seal with petroleum
jelly.
Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Disconnect the output shaft speed (OSS)
sensor electrical connector (colored
black).

2. Connect the OSS sensor electrical connec-

tor (colored black).

3. Remove the OSS sensor.

• Allow the oil to drain into a suitable
container.
• Discard the O-ring seal.

3. Lower vehicle.
4. Start the engine and move the selector
lever through all of the ranges, allowing
sufficient time for each position to engage.
• Engage the selector lever in the "P" (park)
position.
5. Check the transmission fluid level. For
additional information, refer to Preliminary
Inspection in this section.
6. Add automatic transmission fluid, if
necessary.

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307-01A-107 Automatic Transmission/Transaxle — Vehicles With: 307-01A-107
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Halfshaft Seal LH (14 303 0)
2. CAUTION: Use an Allen key to prevent
the piston rod from turning.
Special Tool(s) Loosen the suspension top mount nut by
Installer, Drive Pinion Oil five turns.
Seal
205-077 (15-047 A)

Remover, Halfshaft Oil Seal

308-208 (16-074)

Remover, Halfshaft
308-256 (16-089)

3. Using cable ties, support the radiator on

both sides.

General Equipment
Transmission jack

Name Specification
Cable ties
Automatic transmission fluid ESP-M2C-116-H

Removal
1. Remove the suspension strut and spring
assembly top mount brace cover.

4. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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307-01A-108 Automatic Transmission/Transaxle — Vehicles With: 307-01A-108

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

5. Remove the front wheel and tire. For 9. Remove the exhaust flexible pipe. For
additional information, refer to Section additional information, refer to Section
204-04. 309-00.
6. Remove the splash shield. 10. Remove the engine rear support insula-
tor.

7. Remove the radiator support brackets.

1. Remove the hose bracket. 11. Using two suitable wooden blocks and
suitable transmission jack, support the
2. Remove both radiator support brackets.
subframe.

8. Detach the stabilizer connecting link from

the suspension strut on both sides.

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307-01A-109 Automatic Transmission/Transaxle — Vehicles With: 307-01A-109
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

12. CAUTION: Do not pull down the lower 15. CAUTION: Lower the subframe
arm, to prevent the lower arm hydro- uniformly, to prevent the lower arm
bushing from damage. hydro-bushing from damage.
Remove the lower arm ball joint retaining Using the transmission jack, lower the
nut and bolt. subframe approximately 150 mm.

13. Remove the subframe rear retaining bolts 16. CAUTION: Protect the ball joint seal
and the subframe bracket retaining bolts using a soft cloth to prevent damage.
on both sides.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

14. Remove the subframe front retaining

bolts on both sides.

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307-01A-110 Automatic Transmission/Transaxle — Vehicles With: 307-01A-110

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

17. CAUTION: Support the halfshaft. The

inner joint must not be bent more than Installation
18 degrees. The outer joint must not
be bent more than 45 degrees. 1. Using the special tool, install the halfshaft
Using the special tool, detach the oil seal.
halfshaft from the transaxle and secure it
to one side.
• Allow the oil to drain into a suitable
container.
• Remove and discard the snap ring from the
stub shaft.

2. CAUTION: Support the halfshaft. The

inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
18. Using the special tool, remove the half-
shaft oil seal. CAUTION: Make sure the snap ring is
correctly seated.
NOTE: Install a new snap ring.
Attach the halfshaft to the transaxle.

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307-01A-111 Automatic Transmission/Transaxle — Vehicles With: 307-01A-111
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

3. CAUTION: Make sure the heat shield is 5. Using the special tools and a suitable
installed to prevent damage to the ball washer, align the subframe.
joint. 1. Insert the washer, with inside diameter 22
mm, outside diameter 44 mm and height 5
Attach the lower arm to the wheel knuckle
mm, into the subframe above the lower
on both sides.
alignment hole.
• Install the heat shield.
2. Insert the alignment pin through the
subframe alignment holes and the washer.
3. Slide the locking plates on top of the
washer and into the groove of the tool and
tighten the alignment pin sleeve.

4. Using the transmission jack, position the

subframe.

6. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

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307-01A-112 Automatic Transmission/Transaxle — Vehicles With: 307-01A-112

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

7. CAUTION: While tightening the 9. WARNING: Install a new self-locking

subframe retaining bolts, make sure nut.
the subframe does not move.
Install the lower arm ball joint pinch bolt
Install the subframe front retaining bolts. from the rear, the retaining nut from the
• Lower and remove the transmission jack. front.

8. Remove the special tools. 10. Install the engine rear support insulator.

11. Install the exhaust flexible pipe. For

additional information, refer to Section
309-00.
12. Install the stabilizer connecting link to the
suspension strut on both sides.

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307-01A-113 Automatic Transmission/Transaxle — Vehicles With: 307-01A-113
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

17. Remove the cable ties.
13. Install the radiator support brackets.
1. Install both radiator support brackets.
2. Install the hose bracket.

14. Install the splash shield.

18. CAUTION: Use an Allen key to

prevent the piston rod from turning.
Tighten the suspension top mount nut.

15. Install the wheel and tire. For additional

information, refer to Section 204-04.
16. Lower the vehicle.

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307-01A-114 Automatic Transmission/Transaxle — Vehicles With: 307-01A-114

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

19. Install the suspension strut and spring
assembly top mount brace cover.

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307-01A-115 Automatic Transmission/Transaxle — Vehicles With: 307-01A-115
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Halfshaft Seal RH (14 304 0)
2. CAUTION: Use an Allen key to prevent
the piston rod from turning.
Special Tool(s) Loosen the suspension top mount nut by
Installer, Drive Pinion Oil five turns.
Seal
205-077 (15-047 A)

Remover, Halfshaft Oil Seal

308-208 (16-074)

General Equipment
Transmission jack
3. Using cable ties, support the radiator on
both sides.
Name Specification
Cable ties
Automatic transmission fluid ESP-M2C-116-H

Removal
1. Remove the suspension strut and spring
assembly top mount brace cover.

4. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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307-01A-116 Automatic Transmission/Transaxle — Vehicles With: 307-01A-116

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

5. Remove the front wheel and tire. For 9. Remove the exhaust flexible pipe. For
additional information, refer to Section additional information, refer to Section
204-04. 309-00.
6. Remove the splash shield. 10. Remove the engine rear support insula-
tor.

7. Remove the radiator support brackets.

1. Remove the hose bracket. 11. Using two suitable wooden blocks and
2. Remove both radiator support brackets. suitable transmission jack, support the
subframe.

8. Detach the stabilizer connecting link from

the suspension strut on both sides.

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307-01A-117 Automatic Transmission/Transaxle — Vehicles With: 307-01A-117
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

12. CAUTION: Do not pull down the lower 15. CAUTION: Lower the subframe
arm, to prevent the lower arm hydro- uniformly, to prevent the lower arm
bushing from damage. hydro-bushing from damage.
Remove the lower arm ball joint retaining Using the transmission jack, lower the
nut and bolt. subframe approximately 150 mm.

13. Remove the subframe rear retaining bolts 16. CAUTION: Protect the ball joint seal
and the subframe bracket retaining bolts using a soft cloth to prevent damage.
on both sides.
Detach the lower arm ball joint from the
wheel knuckle.
• Remove the heat shield.

14. Remove the subframe front retaining

bolts on both sides.

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307-01A-118 Automatic Transmission/Transaxle — Vehicles With: 307-01A-118

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

17. CAUTION: Support the halfshaft. The

inner joint must not be bent more than Installation
18 degrees. The outer joint must not
be bent more than 45 degrees. 1. Using the special tool, install the halfshaft
Detach the halfshaft from the transaxle oil seal.
and secure it to one side.
• Remove and discard the center bearing
cap and locknuts.
• Allow the oil to drain into a suitable con-
tainer.

2. CAUTION: Support the halfshaft. The

inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
18. Using the special tool, remove the half- oil seal.
shaft oil seal. NOTE: Install a new center bearing cap and
locknuts.
Attach the halfshaft to the transaxle.
• Install the center bearing cap.

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307-01A-119 Automatic Transmission/Transaxle — Vehicles With: 307-01A-119
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

3. CAUTION: Make sure the heat shield is 5. Using the special tools and a suitable
installed to prevent damage to the ball washer, align the subframe.
joint. 1. Insert the washer, with inside diameter 22
mm, outside diameter 44 mm and height 5
Attach the lower arm to the wheel knuckle
mm, into the subframe above the lower
on both sides.
alignment hole.
• Install the heat shield.
2. Insert the alignment pin through the
subframe alignment holes and the washer.
3. Slide the locking plates on top of the
washer and into the groove of the tool and
tighten the alignment pin sleeve.

4. Using the transmission jack, position the

subframe.

6. CAUTION: While tightening the

subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

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307-01A-120 Automatic Transmission/Transaxle — Vehicles With: 307-01A-120

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

7. CAUTION: While tightening the 9. WARNING: Install a new self-locking

subframe retaining bolts, make sure nut.
the subframe does not move.
Install the lower arm ball joint pinch bolt
Install the subframe front retaining bolts. from the rear, the retaining nut from the
• Lower and remove the transmission jack. front.

8. Remove the special tools. 10. Install the engine rear support insulator.

11. Install the exhaust flexible pipe. For

additional information, refer to Section
309-00.

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307-01A-121 Automatic Transmission/Transaxle — Vehicles With: 307-01A-121
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

12. Install the stabilizer connecting link to the 17. Remove the cable ties.
suspension strut on both sides.

13. Install the radiator support brackets.

1. Install both radiator support brackets.
2. Install the hose bracket.

18. CAUTION: Use an Allen key to

prevent the piston rod from turning.
Tighten the suspension top mount nut.

14. Install the splash shield.

15. Install the wheel and tire. For additional

information, refer to Section 204-04.
16. Lower the vehicle.

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307-01A-122 Automatic Transmission/Transaxle — Vehicles With: 307-01A-122

4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

19. Install the suspension strut and spring
assembly top mount brace cover.

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307-01A-123 Automatic Transmission/Transaxle — Vehicles With: 307-01A-123
4-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Transmission Range (TR) Sensor (17 705 0)

Installation
Special Tool(s)
1. NOTE: Make sure the transaxle is in the
Gauge TR Sensor Alignment NEUTRAL position.
307-351 (17–090)
Position the transmission range (TR) sen-
sor and loosely install the bolts.

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Move the selector lever to neutral "N".
3. Remove the battery tray. For additional
information, refer to Section 414-01.
4. Remove the transmission range (TR)
sensor.
1. Disconnect the TR electrical connector. 2. NOTE: As necessary, move the manual
2. Remove the retaining bolts. control lever to ""N” position for TR sensor
adjustment.
Rotate the manual valve detent lever
assembly to the neutral position.
1. Low 1
2. Low 2
3. Drive
4. Neutral
5. Reverse
6. Park

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4-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

3. Install the TR sensor.
1. Using the special tool, align the TR sensor.
2. Tighten the retaining bolts and remove the
special tool.
3. Connect the electrical connector.

4. Install the battery tray. For additional

information, refer to Section 414-01.
5. Connect the battery ground cable.
6. Check the correct operation. With parking
brake applied the engine should start only
in park "P" or neutral "N". Reversing
lamps should illuminate only when
Reverse "R" is selected.

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307-01A-125 Automatic Transmission/Transaxle — Vehicles With: 307-01A-125
4-Speed Automatic Transaxle

REMOVAL
Transaxle (17 214 0)
REMOVAL

Removal
Special Tool(s)
All Vehicles
Support Bar, Engine
1. NOTE: The locations of engine and transaxle
303-290A (21-140A) mountings and engine support insulators are
described looking from the transaxle to the
engine.
Disconnect the battery ground cable. For
Adapter for 303-290A additional information, refer to Section
303–290–01 (21–140–01) 414-01.
2. Detach the pipes and hoses from the en-
gine upper cover.

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Adapter for 303-290A

3. Remove the engine upper cover.
303-290-05A (21-140-05A)

Remover, Halfshaft
308-256 (16-089)

General Equipment
Securing straps
Transmission jack
Tire lever

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4-Speed Automatic Transaxle

REMOVAL (Continued)
4. Remove the strut and spring assembly top 7. Detach the selector lever cable from the
mount brace cover. transaxle.
1. Remove the selector lever cable bracket.
2. Detach the selector lever cable.

5. CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Loosen the strut and spring assembly top 8. Raise and support the vehicle. For
mount nut by five turns. additional information, refer to Section
100-02.
9. Remove the radiator splash shield.

6. Remove the air cleaner. For additional

information, refer to Section 303-01A / 303-
01B / 303-01C / 303-01D. 10. Remove the subframe. For additional
information, refer to Section 502-00.
11. Remove the accessory drive belt cover.

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4-Speed Automatic Transaxle

REMOVAL (Continued)
12. Remove the transaxle drain plug and All vehicles
drain the transmission fluid. 14. NOTE: The electrical connector color is
• Discard the gasket. black.
• Allow the oil to drain into a suitable con- Disconnect the output shaft speed (OSS)
tainer. sensor electrical connector.

Vehicles with Xenon headlamps

15. CAUTION: The inner joint must not be
13. Disconnect the headlamp levelling sen-
bent more than 18 degrees, the outer
sor electrical connector.
joint must not be bent more than 45
degrees.
Detach the right-hand front drive
halfshaft and intermediate shaft.
1. Remove the centre bearing cap.
2. Remove the intermediate shaft from the
transaxle.
• Using cable ties, secure the right-hand
front drive halfshaft.
• Using a suitable plug, close off the trans-
axle opening.

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4-Speed Automatic Transaxle

REMOVAL (Continued)

16. CAUTION: The inner joint must not be 18. NOTE: The electrical connector color is
bent more than 18 degrees, the outer white.
joint must not be bent more than 45 Disconnect the turbine shaft speed (TSS)
degrees. sensor electrical connector.
Detach the left-hand front drive halfshaft. • Remove the cable retaining clip.
• Using the special tool, detach the halfshaft
from the transaxle.
• Using cable ties, secure the left-hand front
drive halfshaft.
• Using a suitable plug, close off the trans-
axle opening.

19. CAUTION: Prevent the fluid pipe

adapter from turning using an open-
end spanner, do not remove it from
the transaxle housing.
Detach the fluid cooler pipe from the
transaxle.
17. CAUTION: Prevent the fluid pipe • Close off the openings using suitable
adapter from turning using an open- plugs.
end spanner, do not remove it from
the transaxle housing.
Detach the fluid cooler pipe from the
transaxle.
• Detach the fluid pipe bracket from the
transaxle.
• Close off the openings using suitable
plugs.

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307-01A-129 Automatic Transmission/Transaxle — Vehicles With: 307-01A-129
4-Speed Automatic Transaxle

REMOVAL (Continued)
20. Remove the wiring harness and fluid 24. Disconnect the automatic transmission
cooler pipe bracket. control electrical connector.
• Detach the fluid cooler pipe. • Remove the wiring harness retaining clip.
• Detach the wiring harness. • Remove the cable ties.

21. Remove the starter motor. 25. Remove the plastic cover from the hood.

22. Lower the vehicle. 26. Remove the bulkhead cover.

23. Disconnect the transmission range (TR)
sensor electrical connector.

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4-Speed Automatic Transaxle

REMOVAL (Continued)
30. Raise and support the vehicle. For
additional information, refer to Section
27. CAUTION: Do not damage coating of 100-02.
the fender.
31. Remove the rubber cover and the four
Install the special tools. torque converter to engine drive plate
• Secure the engine. nuts.
• Rotate the torque converter to gain access
to remaining nuts.
• Discard the nuts

28. Detach the rear engine and transaxle

mounting.

32. NOTE: Use a suitable wooden block and

securing straps.
Using a transmission jack and wooden
block support the transaxle.
• Secure the transaxle with securing straps.

29. Remove the rear engine and transaxle

mounting bracket.

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4-Speed Automatic Transaxle

REMOVAL (Continued)
33. Remove the transaxle retaining bolts
(transaxle removed for clarity).

34. CAUTION: Make sure that the torque

converter remains in the transaxle.
Using a transmission jack lower the
transaxle.

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307-01A-132 Automatic Transmission/Transaxle — Vehicles With: 307-01A-132
4-Speed Automatic Transaxle

DISASSEMBLY
Transaxle (17 214 8)
DISASSEMBLY

Disassembly
Special Tool(s)
1. CAUTION: In the case of abraded
Remover/Installer, Lower particles of metal, install a new valve
Arm Bushing body, fluid pipes, fluid cooler and
204-168 (14-043) torque converter.
NOTE: Clean the transaxle assembly to prevent
the entry of dirt when reassembling.
Slide Hammer NOTE: Do not clean brake band and friction
plates with cleaning agents.
205-047 (15-011)
NOTE: If, during repair work, abraded particles
are found in the transmission fluid (particles from
the clutch or metal chips or debris), the transaxle
must be disassembled completely and cleaned.
Remover, Torque Converter Also, clean fluid pipes, fluid cooler and torque
Oil Seal converter carefully; in case of extreme soiling the
307-272 (17-061) fluid pipes, fluid cooler and torque converter
should be newly installed.
NOTE: In case of clutch abrasion, rinse the
torque converter with clean automatic
Mouting Stand transmission fluid.
303-435 (21-187) NOTE: Before taking measurements, compress
all the clutches where axial play is detected to
squeeze the oil out from between the plates.
Inspect transaxle during disassembly.
Mounting Bracket for 303- 2. CAUTION: Do not tilt the torque
435 converter when removing it to avoid
303-435-06 (21-031B) damaging the torque converter hub.
NOTE: The torque converter is filled with fluid.
Position it on a table so that fluid will drain out of
the torque converter into a drain pan.
Mounting Plate for 303-435-
06 Remove the torque converter.
303-435-13 (21-170A)

General Equipment
Inside puller

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307-01A-133 Automatic Transmission/Transaxle — Vehicles With: 307-01A-133
4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
3. Remove the output shaft speed (OSS) 6. Remove the pump assembly driveshaft.
sensor.
• Remove and discard the OSS sensor O-
ring seal.

7. Using the special tools, remove and dis-

card the torque converter impeller hub
seal.
4. Using the special tool, secure the trans-
axle.

8. Using the special tools, remove the left-

hand and right-hand differential seals.
5. Position the drain pan under the transaxle, 1. Install the special tool.
remove the drain plug, and drain the 2. Install the special tool.
transmission fluid. 3. Remove and discard the differential seals.
• Discard the gasket.

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4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
9. Remove the turbine shaft speed (TSS) 12. Remove the transaxle fluid filler tube.
sensor.
1. Remove the bolt.
2. Remove the TSS sensor.

13. Remove and discard the transaxle filler

tube grommet.

10. Remove and discard the TSS sensor O-

ring seal.

14. Remove the transmission range (TR)

sensor.
1. Remove the bolts.
11. Remove the transaxle fluid filler tube bolt. 2. Remove the TR sensor from the manual
valve detent lever shaft.

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307-01A-135 Automatic Transmission/Transaxle — Vehicles With: 307-01A-135
4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
15. Remove the main control cover bolts, and 17. Inspect the fitting of the main control
cover. cover vent tube for blockage (if avail-
able).

18. Remove the solenoid body assembly wir-

ing harness retaining clip.

16. Remove and discard the gasket.

19. CAUTION: Only remove the indicated

bolts.
Remove the main control valve body
bolts.

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4-Speed Automatic Transaxle

DISASSEMBLY (Continued)

20. CAUTION: Do not allow loose manual 22. Support the manual valve and remove the
valve to become damaged. main control.
• Store the main control in a clean, dry loca-
Disconnect the manual valve link from
tion.
the manual valve when lifting the main
control valve body from the case.

23. Remove the thermostatic fluid level con-

trol valve bracket.
21. CAUTION: Do not pull solenoid body
electrical connector wires, or don't
use a hammer on the electrical
connector.
Remove the solenoid body electrical
connector.
• Release the retaining tabs and push the
connector through the transaxle case.

24. Remove the thermostatic fluid level con-

trol valve.

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307-01A-137 Automatic Transmission/Transaxle — Vehicles With: 307-01A-137
4-Speed Automatic Transaxle

DISASSEMBLY (Continued)

25. WARNING: The servo is under 27. Inspect the intermediate and overdrive
pressure. servo assembly and bore for damage or
wear.
WARNING: Servo and servo cover are 1. Inspect the servo cover and bonded seal.
under high spring force. Use caution
2. Inspect the cushion spring and servo apply
when removing servo cover. Failure to
rod.
follow these instructions will result in
personal injury. 3. Inspect the servo return spring.
NOTE: To aid in the removal of the servo cover, • Inspect the case servo bore.
install a nut with an integral washer N621943-S2
(using permanent thread sealer) onto the forcing
bolt of the servo cover.
Compress the servo cover and remove
the snap ring.

28. NOTE: Position the transaxle with the torque

converter housing facing upward.
Remove the 20 bolts.

26. Remove the servo piston assembly.

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4-Speed Automatic Transaxle

DISASSEMBLY (Continued)

29. NOTE: Place the torque converter housing on 31. Unsnap and remove the chain pan cover.
the engine flange side after removal to prevent
damage to the lube tube.
Separate the torque converter housing
from the transaxle case.
• Remove and discard the transaxle split
flange gasket.

32. Remove the No. 13 driven sprocket thrust

bearing.

30. Remove the final drive carrier and

differential assembly.
1. Remove the No. 15 differential bearing.
2. Remove the No. 14 differential bearing
shim.
3. Remove the final drive carrier and differen-
tial assembly.

33. NOTE: The driven sprocket thrust washer

may adhere to the converter housing.
Remove the No. 10 driven sprocket thrust
washer from the reverse/overdrive ring
gear assembly.

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307-01A-139 Automatic Transmission/Transaxle — Vehicles With: 307-01A-139
4-Speed Automatic Transaxle

DISASSEMBLY (Continued)

34. WARNING: Wear gloves as protection 36. NOTE: Inspect the magnet located on the
from sharp chain and sprocket teeth. chain pan for excessive metal particles.
Failure to follow these instructions Remove the chain pan (with the magnet
will result in personal injury. attached) from the transaxle case.
Remove the chain drive, re-
verse/overdrive ring gear, and driven
sprocket assembly.

37. Remove the filter recirculation exhaust

pipe using an inside puller.
• Discard the exhaust pipe.
35. Separate the drive chain assembly from
the driven sprocket assembly and re-
verse/overdrive ring gear assembly.

38. Remove the fluid filter and seal

assembly.
1. Discard the fluid filter.
2. Discard the fluid filter seal.

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307-01A-140 Automatic Transmission/Transaxle — Vehicles With: 307-01A-140

4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
42. Disconnect the parking lever actuation
39. Remove the No. 12 driven sprocket bear-
rod from the manual valve detent lever,
ing.
and remove the parking lever actuation
rod.

40. Remove the No. 11 driven sprocket shim

(selective fit).
43. NOTE: The thrust bearing may adhere to the
reverse/overdrive sprocket.
Remove the No. 9 reverse/overdrive ring
gear thrust bearing.

41. Disconnect the parking lever actuating

rod from the parking cam actuator lever
assembly.

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307-01A-141 Automatic Transmission/Transaxle — Vehicles With: 307-01A-141
4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
44. NOTE: The thrust bearing is part of the 47. Remove the low-intermediate ring gear
reverse/overdrive carrier assembly. assembly.
Remove the reverse/overdrive carrier as-
sembly with captured No. 8 thrust bear-
ing.

48. NOTE: The low-intermediate carrier thrust

bearing may adhere to the low-intermediate
ring gear.
45. Remove the reverse/overdrive sun gear Remove the No. 6 low-intermediate car-
and shell assembly. rier thrust bearing.

46. NOTE: The thrust bearing may adhere to the 49. Remove the low-intermediate carrier as-
reverse/overdrive sun gear and shell. sembly.
Remove the reverse/overdrive sun gear
and No. 7 shell thrust bearing.

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307-01A-142 Automatic Transmission/Transaxle — Vehicles With: 307-01A-142

4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
50. Remove the No. 5 low-intermediate sun 53. Remove the turbine shaft assembly.
gear thrust bearing.

54. Remove the forward/coast/direct clutch

51. Remove the forward one-way clutch and cylinder assembly and reverse clutch
low/intermediate sun gear. drum assembly from the transaxle.

52. NOTE: The turbine shaft thrust bearing may 55. NOTE: The pump support thrust bearing
adhere to the forward one-way clutch and assembly may adhere to the reverse clutch
low/intermediate sun gear. drum assembly.
Remove the No. 4 turbine shaft thrust Remove the No. 1 pump support thrust
bearing. bearing.

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307-01A-143 Automatic Transmission/Transaxle — Vehicles With: 307-01A-143
4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
56. Remove the low one-way clutch retaining 59. Remove the low/reverse clutch plates.
ring. • Inspect the friction plates for partially
stripped, stripped, broken or bent spline
teeth, burnt, worn or flaked off friction
material, and warped or bent friction discs.
• Inspect the steel plates for heat discolora-
tion or distortion.

57. Remove the low one-way clutch thrust

plate.

60. Remove the thick, ten-wave low/reverse

clutch wave spring.

58. Remove the thin, eight wave low/reverse

clutch wave spring.

61. Remove the low/reverse clutch return

spring retaining ring.

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307-01A-144 Automatic Transmission/Transaxle — Vehicles With: 307-01A-144

4-Speed Automatic Transaxle

DISASSEMBLY (Continued)
62. Remove the low/reverse clutch return 65. Remove the pump assembly.
spring assembly. • Using a hammer handle, remove the pump
assembly.

63. NOTE: Rotate the low/reverse clutch piston

while pulling upward. 66. Remove the intermediate and overdrive
Remove the low/reverse clutch piston. band assembly from the case.
• Inspect the intermediate and overdrive
band assembly for damage and wear.

64. NOTE: Position the transaxle that the pump

assembly is facing upward.
Remove the pump assembly bolts.

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307-01A-145 Automatic Transmission/Transaxle — Vehicles With: 307-01A-145
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Chain Sprockets
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

2. Using an internal puller, remove the stator

support bearing.
Special Tool(s)
Installer, Wheel Hub Bearing
Cone/Oil Seal
205-101 (15-051)

Installer, Needle Bearing

307-294 (17-053)

General Equipment
Internal puller
Assembly
1. NOTE: The stamped part number on the
reverse and overdrive ring gear bearing must
Disassembly face the special tool.
1. Using an internal puller, remove the re- Using the special tool, install the reverse
verse and overdrive ring gear bearing. and overdrive ring gear bearing.

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307-01A-146 Automatic Transmission/Transaxle — Vehicles With: 307-01A-146

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

2. NOTE: The stamped part number on the stator
support bearing must face the special tool.
Using the special tools, install the stator
support bearing into the stator support
sprocket.

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307-01A-147 Automatic Transmission/Transaxle — Vehicles With: 307-01A-147
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Torque Converter Housing
3. Remove the final drive ring gear.
• Remove the retaining ring.
Special Tool(s)
Installer, Oil Fill Pipe
307-307 (17-065)

Disassembly
1. Remove and discard the transmission fluid
cooler tube adaptor.

4. Inspect the final drive ring gear and hous-

ing lug teeth for damage or wear.

2. Remove and discard the sealing and the

plastic washer.

5. Remove the differential lube tube.

1. Remove the retaining bolt.
2. Remove the differential lube tube from the
housing.

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4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

6. WARNING: In order to avoid injury, eye 8. Check for blockage at the torque converter
protection should be worn when seal return hole.
cleaning components with
compressed air. Failure to follow
these instructions will result in
personal injury.
NOTE: Clean all components with a suitable
solvent and use moisture-free compressed air to
dry all parts and clean fluid passages.
Inspect the converter housing.
• Inspect the stator support area for wear.
• Inspect the differential bushing for wear.
• Inspect the case mating surfaces for nicks
or deformation.
7. Check the converter housing hydraulic
passages for blockage.
1. Check the differential lubrication passage. Assembly
2. Check the front lubrication passage.
3. Check the converter turbine passage. 1. Locate a new differential lube tube in the
torque converter housing.
4. Check the converter impeller passage.
5. Check the transmission fluid cooler pas-
sage.

2. Using the special tool, install the differen-

tial lube tube.

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307-01A-149 Automatic Transmission/Transaxle — Vehicles With: 307-01A-149
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Install the differential lube tube retaining 6. NOTE: Install a new transmission fluid cooler
bolt. tube adaptor.
Install the transmission fluid cooler tube
adaptor.

4. NOTE: The final drive ring gear is installed

with the lug end up.
Install the final drive ring gear.
• Install the retaining ring.

5. Install a new sealing and plastic washer.

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307-01A-150 Automatic Transmission/Transaxle — Vehicles With: 307-01A-150
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Final Drive Carrier and Differential Assembly
2. Inspect the final drive planet and carrier
for damage.
General Equipment 1. Inspect the pinion gear teeth.
2. Inspect the thrust bearing surfaces.
Feeler gauge
3. Inspect the bushing surfaces.

Disassembly
1. NOTE: If damage is detected during the
checking procedure, the differential should be
replaced.
Inspect the differential for damage.
1. Inspect the differential housing.
2. Inspect the differential bearing shim.
3. Inspect the differential housing bearing.
4. Inspect the pinion shaft roll pin.
5. Inspect the pinion shaft.
6. Inspect the pinion thrust washer.
3. CAUTION: Do not disassemble the
7. Inspect the pinion gear. planet carrier.
8. Inspect the side gear thrust washer. NOTE: If the measurement exceeds
9. Inspect the differential side gear. specification, install a new final drive carrier.
Using a feeler gauge, measure the final
drive planet gear end play.

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307-01A-151 Automatic Transmission/Transaxle — Vehicles With: 307-01A-151
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. NOTE: Do not remove the final drive pinion 7. Clean all parts thoroughly in clean solvent
shaft retaining ring. and blow dry with moisture-free regulated
compressed air.
Remove the differential pinion shaft.
8. Inspect the differential components for
1. Remove the pinion shaft roll pin.
damage and wear.
2. Remove the differential pinion shaft.
• Inspect the gear teeth.
• Inspect the thrust washer surface.
• Inspect the thrust bearing surface.
• Inspect the pinion shaft.

Assembly
1. Install the differential side gears and thrust
washers.

5. Remove the pinion gears and thrust

washers.
• Turn the differential pinion gears through
90 degrees and remove.

2. Install the differential pinion gears and

thrust washers.
• Rotate the differential pinion gears through
90 degrees to align with pinion shaft.

6. Remove the differential side gears and dif-

ferential side gear thrust washers.

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307-01A-152 Automatic Transmission/Transaxle — Vehicles With: 307-01A-152

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Install the differential pinion shaft.
1. Install the pinion shaft.
2. Install the roll pin.

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307-01A-153 Automatic Transmission/Transaxle — Vehicles With: 307-01A-153
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Forward/Coast/Direct Clutch Cylinder and Reverse Clutch Drum - Assembly

Disassembly
Special Tool(s)
Protector Piston Seal
307-278 (17-060-04)

Item Part Description

Number
1 - Reverse clutch
2 - Direct clutch
3 - Forward/coast clutch

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307-01A-154 Automatic Transmission/Transaxle — Vehicles With: 307-01A-154

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

1. NOTE: Use a suitable wooden block to support 4. Remove the direct clutch hub and shell
the forward, coast and direct clutch cylinder from the forward, coast and direct clutch
assembly. cylinder.
Remove the reverse clutch hub retaining
ring.

5. Remove and discard the two reverse

clutch cylinder seals from the forward,
coast and direct clutch cylinder assembly.
2. Remove the reverse clutch hub.

6. Remove the No. 2 direct clutch thrust

3. Remove the reverse clutch drum assem-
washer from the forward, coast and direct
bly.
clutch cylinder.

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307-01A-155 Automatic Transmission/Transaxle — Vehicles With: 307-01A-155
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

7. Remove and discard the forward, coast 2. NOTE: Make sure that the reverse clutch
and direct clutch cylinder hub seal. cylinder seals are overlapped correctly.
Position the reverse clutch cylinder seals.
1. Correct installation
2. Incorrect installation

Assembly
1. CAUTION: The tabs on the No. 2 direct
3. Install the two reverse clutch cylinder
clutch thrust washer must be seated
seals.
in the direct clutch support and
spring.
Install the No. 2 direct clutch thrust washer
on the forward, coast and direct clutch cyl-
inder with the tabs facing downward.

4. Using a suitable wooden block to assist in

installation, install the direct clutch hub
and shell on the forward, coast and direct
clutch cylinder.

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4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

5. Install the reverse clutch drum assembly. 8. NOTE: Turn the forward, coast and direct
clutch cylinder over.
Install the forward, coast and direct clutch
cylinder hub seal.

6. Install the reverse clutch hub.

9. Using the special tool, size the seal. Leave

special tool attached until the for-
ward/coast/direct clutch cylinder is in-
stalled into the transaxle housing.

7. Installing the reverse clutch hub retaining

ring.

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307-01A-157 Automatic Transmission/Transaxle — Vehicles With: 307-01A-157
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Forward/Coast/Direct Clutches
Special Tool(s)
Protector, Piston Seal
Special Tool(s) 307-277 (17-060-03)
Remover, O-Ring
100-010 (17-063)

General Equipment

Compressor, Clutch Spring Holding fixture, dial indicator gauge

307-015 (17-058)
Name Specification
Automatic transmission ESP-M2C166-H
fluid

Disassembly

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307-01A-158 Automatic Transmission/Transaxle — Vehicles With: 307-01A-158
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Item Part Description

Item Part Description Number
Number
4 7B442 Direct clutch external spline
1 7D483 Direct clutch pressure plate clutch plates (steel)
retaining ring
5 7C122 Direct clutch spring retaining
2 7B477 Direct clutch pressure plate ring
3 7B164 Direct clutch internal spline 6 7F235 Direct clutch return spring
clutch plates (friction)
7 7F225 Direct clutch piston inner lip
seal

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307-01A-159 Automatic Transmission/Transaxle — Vehicles With: 307-01A-159
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

Item Part Description 1. Remove the direct clutch pressure plate
Number retaining ring.

8 7A262 Direct clutch piston assem-

bly
9 7A548 Direct clutch piston outer lip
seal
10 7G120 Forward, coast and direct
clutch cylinder assembly
11 7A548 Forward clutch piston inner
lip seal
12 7A262 Forward clutch piston as-
sembly
13 7A548 Forward clutch piston outer
lip seal 2. Disassemble the direct clutch pack.
14 7A262 Coast clutch piston and seal 1. Remove the direct clutch pressure plate.
assembly 2. Remove the direct clutch plates.
15 7G299 Forward, coast clutch return
spring
16 7N169 Forward clutch spring retain-
ing ring
17 -- Clearance for fingers on the
forward clutch piston
18 7B442 Coast clutch external spline
clutch plates (steel)
19 7B164 Coast clutch internal spline
clutch plates (friction)
20 7B066 Coast clutch pressure plate
21 74159 Forward clutch wave spring
22 7B164 Forward clutch internal
spline clutch plates (friction)
23 7B442 Forward clutch external
spline clutch plates (steel)
24 7B066 Forward clutch pressure
plate
25 7D483 Forward clutch pressure
plate retaining ring

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307-01A-160 Automatic Transmission/Transaxle — Vehicles With: 307-01A-160

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. WARNING: Use caution when releasing 5. Remove the direct clutch piston assembly.
tool pressure on the clutch piston
springs. Failure to follow these
instructions may result in personal
injury.
CAUTION: Do not compress the direct
clutch return springs completely.
Remove the direct clutch spring retaining
ring.
1. Using the special tool, compress the direct
clutch return springs.
2. Remove the direct clutch return spring re-
taining ring.

4. Remove the direct clutch return spring as- 6. Remove and discard the direct clutch pis-
sembly. ton outer lip seal.

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307-01A-161 Automatic Transmission/Transaxle — Vehicles With: 307-01A-161
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

7. Remove and discard the direct clutch pis- 9. Remove the forward and coast clutch
ton inner lip seal from the forward, coast plates.
and direct clutch cylinder assembly. 1. Remove the forward clutch pressure plate.
2. Remove the forward clutch external spline
clutch plates (steel).
3. Remove the coast clutch internal spline
clutch plates (friction).
4. Remove the coast clutch external spline
clutch plates (steel).
5. Remove the coast clutch pressure plate.
6. Remove the forward clutch internal spline
clutch plates (friction).
7. Remove the forward clutch wave spring.

8. Remove the forward clutch pressure plate

retaining ring from the forward, coast and
direct clutch cylinder assembly.

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307-01A-162 Automatic Transmission/Transaxle — Vehicles With: 307-01A-162

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

10. WARNING: Use caution when 12. Remove the forward and coast clutch pis-
releasing tool pressure on the clutch tons.
piston springs. Failure to follow these
instructions may result in personal
injury.
CAUTION: Do not fully compress the
return springs.
Remove the forward and coast clutch
return spring retaining ring.
1. Using the special tool, compress the return
spring.
2. Remove the retaining ring.

13. Using the special tool, remove and dis-

card the forward clutch piston inner seal
from the forward, coast and direct clutch
cylinder assembly.

11. Remove the forward and coast clutch re-

turn spring assembly.

14. Remove and discard the forward clutch

piston outer lip seal.

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307-01A-163 Automatic Transmission/Transaxle — Vehicles With: 307-01A-163
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

15. Separate the coast clutch piston assem- 2. Install the forward clutch piston inner seal
bly from the forward clutch piston as- on the forward, coast and direct clutch cyl-
sembly. inder assembly.

16. NOTE: Do not clean the clutch plates in a 3. Install the forward clutch piston outer lip
vapor degreaser or in any other type of seal on the forward clutch piston assem-
detergent solution. bly.
Clean all parts thoroughly in a clean
solvent and blow dry with moisture-free
regulated compressed air.
• Clean the clutch plates with a lint-free
cloth.
17. Inspect the parts for damage or wear.
• Inspect the spline teeth.
• Inspect the clutch plates.
• Inspect the seals.
• Inspect the bushing.
• Inspect the check balls in pistons.
• Inspect the piston bore.
• Inspect the forward, coast and direct clutch 4. Install the forward clutch piston assembly
cylinder lubrication passages. in the forward, coast and direct clutch cyl-
inder assembly.
Assembly
1. Soak the internal spline clutch plates in
clean automatic transmission fluid for 15
minutes before assembly.

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307-01A-164 Automatic Transmission/Transaxle — Vehicles With: 307-01A-164

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

5. NOTE: The select fit retaining ring must be 8. Using the special tool, install the coast
centered between two adjacent legs. clutch piston into the forward clutch pis-
ton assembly.
Using a felt tip marker (do not use a paint
pen) mark the center of two adjacent legs
on the top of the cylinder.

9. Install the forward and coast clutch return

spring assembly.
6. Using a felt tip marker (do not use a paint
pen) mark the cylinder at the center point
between the marks on the two adjacent
legs.

7. Install the coast clutch piston assembly

onto the special tool.

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307-01A-165 Automatic Transmission/Transaxle — Vehicles With: 307-01A-165
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

10. WARNING: Use caution when 11. Install the forward and coast clutch
releasing tool pressure on the clutch plates in the sequence shown.
piston springs. Failure to follow these 1. Install the coast clutch external spline
instructions may result in personal clutch plates (steel).
injury. 2. Install the coast clutch internal spline clutch
plates (friction).
CAUTION: Do not compress the return
springs completely. 3. Install the coast clutch pressure plate.
4. Install the forward clutch wave spring.
Using the special tool, remove the
forward/coast clutch return spring 5. Install the forward clutch internal spline
retaining ring. clutch plates (friction).
1. Compress the return spring. 6. Install the forward clutch internal spline
clutch plates (steel).
2. Remove the retaining ring.
7. Install the forward clutch pressure plate.
• Align the gap between the piston legs.

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307-01A-166 Automatic Transmission/Transaxle — Vehicles With: 307-01A-166

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

12. Position the select fit retaining ring on 14. Install the direct clutch piston inner lip
the center mark between the two adjacent seal on the direct clutch cylinder assem-
legs. bly.

13. Measure the clearance between the 15. Install the direct clutch piston outer seal
forward clutch pressure plate and the on the direct clutch piston assembly.
forward clutch pressure plate retaining
ring with a feeler gauge.
• Repeat the measurement on the opposite
side.
• Average the two measurements to get the
clearance.
• If the clearance is not within specification,
select and install the proper thickness
retaining ring to obtain the standard
clearance.
• Retaining ring sizes:
• 1.43 - 1.53 mm
• 1.59 - 1.69 mm
• 1.75 - 1.85 mm
• 1.92 - 2.02 mm

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307-01A-167 Automatic Transmission/Transaxle — Vehicles With: 307-01A-167
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

16. NOTE: Position the lip seal facing down. 18. WARNING: Use caution when
Install the direct clutch piston assembly releasing tool pressure on the clutch
in the forward, coast and direct clutch piston springs. Failure to follow these
cylinder assembly. instructions may result in personal
injury.
CAUTION: Do not fully compress the
direct clutch return springs.
Using the special tool, install the direct
clutch return spring retaining ring.
1. Compress the direct clutch return springs.
2. Install the direct clutch return spring retain-
ing ring.

17. Install the direct clutch return spring as-

sembly.

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307-01A-168 Automatic Transmission/Transaxle — Vehicles With: 307-01A-168

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

19. Install the direct clutch plates. 21. Measure and adjust the clearance of the
1. Install the direct clutch external spline direct clutch.
(steel) clutch plates. • Attach a dial gauge to the direct clutch.
2. Install the direct clutch internal spline
(friction) clutch plates.
3. Install the direct clutch pressure plate.

22. Measure and adjust the direct clutch play.

1. Mount a dial gauge onto the thrust washer.
• Press the pack of clutch plates together
and zero the dial gauge on the thrust
washer.
2. Lift the pressure plate as far as possible
using two scribers on opposite sides.
3. Note the axial clearance displayed on the
dial gauge.
• Rotate through 180 degrees and repeat the
measurement.
• Calculate the average of the two values.
• Permissible axial clearance:
• With three friction plates: 0,52 - 1,12 mm
• With four friction plates: 0,73 - 1,42 mm
20. Install the direct clutch pressure plate • The snap-ring for the clutch plate assembly
retaining ring. is used to correct the axial clearance and is
available in different thicknesses:
• 1,28 mm - 1,38 mm
• 1,39 mm - 1,49 mm
• 1,52 mm - 1,62 mm
• 1,65 mm - 1,75 mm

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307-01A-169 Automatic Transmission/Transaxle — Vehicles With: 307-01A-169
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

G37611 en 08/2002 2003.0 Mondeo

307-01A-170 Automatic Transmission/Transaxle — Vehicles With: 307-01A-170
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Forward One-Way Clutch

Disassembly

Forward one-way clutch 1. Remove the coast clutch hub retaining

ring.
Item Part Description
Number
1 – Coast clutch hub retaining
ring
2 – Coast clutch hub
3 – Forward one-way clutch
outer ring
4 – Forward one-way clutch end
cap
5 - Forward one-way clutch
6 - Forward one-way clutch end
cap
7 – Forward one-way retainer
8 – Low intermediate sun gear,
race and bushing assembly

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307-01A-171 Automatic Transmission/Transaxle — Vehicles With: 307-01A-171
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

2. Remove the coast clutch hub. 5. Remove the forward one-way clutch re-
tainer.

3. Remove the forward one-way clutch outer

ring and forward one-way clutch with the 6. Remove the retaining ring downward over
end caps. the gear.

4. NOTE: Orientation of the end caps forward 7. WARNING: Wear protective goggles
one-way clutch. New design end caps are of when using compressed air to clean
the same thickness and interchangeable (but components.
not reversible).
NOTE: Not all transaxles contain the forward Thoroughly clean all components and
one-way clutch style shown. blow them dry with moisture-free regulated
compressed air.
Remove the forward one-way clutch end
caps from the forward one-way clutch.

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307-01A-172 Automatic Transmission/Transaxle — Vehicles With: 307-01A-172

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8. Inspect the forward one-way clutch 3. NOTE: Orientation of the forward one-way
components for damage and wear. clutch end caps. New design end caps are of
• Inspect the forward one-way clutch. the same thickness and interchangeable (but
not reversible).
• Inspect the forward one-way clutch and
end caps. Install the forward one-way clutch end
• Inspect the inner race and low-intermediate caps onto the forward one-way clutch.
sun gear assembly.
• Inspect the lube holes.
• Inspect the coast clutch hub.

Assembly
1. Install the retaining ring.

4. Install the forward one-way clutch and end

caps in the forward one-way clutch outer
ring.

2. NOTE: The tabs on the forward one-way

clutch retainer face downward.
Install the forward one-way clutch retainer.

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307-01A-173 Automatic Transmission/Transaxle — Vehicles With: 307-01A-173
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

5. NOTE: Lube grooves face upward (away from
8. Check the operation of the forward one-
the sun gear) forward one-way clutch.
way clutch with the low-intermediate sun
Install the forward one-way clutch outer gear facing upward.
ring and one-way clutch on the forward • Hold the outer race firmly.
one-way clutch inner race by rotating
• Rotate the low-intermediate sun gear
them.
clockwise.
• The low-intermediate sun gear should
rotate with a slight drag without attempting
to rotate the outer race.
• Rotate the low-intermediate sun gear coun-
terclockwise; the low-intermediate sun gear
should rotate the outer race.

6. Install the coast clutch hub.

7. NOTE: The ends of the retaining ring should

point toward the coast clutch hub.
NOTE: Make sure the retaining ring is fully
seated upon installation.
Install the coast clutch hub retaining ring.

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307-01A-174 Automatic Transmission/Transaxle — Vehicles With: 307-01A-174
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Low/Reverse Piston

1. Install a new outer seal for the 1st and re-

verse gear servo piston.

2. Install a new inner seal for the 1st and re-

verse gear servo piston.

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307-01A-175 Automatic Transmission/Transaxle — Vehicles With: 307-01A-175
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Low One-Way Clutch Assembly

Disassembly 3. Remove the inner race.

1. Inspect the low one-way clutch
components:
1. Inspect the inner race.
2. Inspect the roller assembly.
3. Inspect the outer race.
4. Identification groove
5. Identification groove

4. Remove the roller assembly.

2. Position the low one-way clutch so that the

inner and outer race grooves are facing
upward.

5. Clean all parts thoroughly in clean solvent

and blow dry with moisture-free regulated
compressed air.

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307-01A-176 Automatic Transmission/Transaxle — Vehicles With: 307-01A-176

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

6. Inspect the low one-way clutch parts for 3. Check the operation of the one-way clutch
damage and wear. as follows:
• Inspect the outer race. 1. Hold the outer race in place.
• Inspect the roller assembly. 2. Turn the inner race clockwise. It must be
• Inspect the inner race. possible to turn the inner race slowly
against the outer race.
• Inspect the lubrication holes.
3. Turn the inner race anti-clockwise. The in-
ner race should force the outer race to turn
Assembly in the same direction.

1. NOTE: Outer tabs of the roller assembly must

face up.
Install the roller assembly into the outer
race.

2. CAUTION: The inner race groove must

be facing upwards.
NOTE: To aid the inner race installation, rotate
the inner race clockwise during installation.
Install the inner race into the roller
assembly.
1. Align tabs with the locating groove.

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307-01A-177 Automatic Transmission/Transaxle — Vehicles With: 307-01A-177
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Main Control Valve Body
3. Remove and discard the solenoid valve
body gasket.
Special Tool(s)
Alignment Pins, Valve Body
307-299 (17-054)

Name Specification
Automatic transmission fluid ESP-M2C166-H

Disassembly
4. Remove the three pressure tap plate re-
1. Remove the manual valve. taining bolts and the pressure tap plate.

2. CAUTION: Do not attempt to remove 5. Remove and discard the pressure plate tap
the solenoid valve body wiring cover. gasket.
Remove the two solenoid valve body re-
taining bolts and remove the solenoid
valve body.

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307-01A-178 Automatic Transmission/Transaxle — Vehicles With: 307-01A-178

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

6. Remove the control valve body-to-transfer 8. Separate the accumulator body from the
plate retaining bolts, and remove the man- main control valve body.
ual valve detent spring assembly. 1. Remove the accumulator body assembly.
2. Remove and discard the accumulator body
separator gasket.
3. Remove the accumulator body separator
plate.
4. Remove and discard the accumulator body
separator gasket.
5. Remove the main control valve body.

7. Remove the accumulator body-to-transfer

plate retaining bolts.

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307-01A-179 Automatic Transmission/Transaxle — Vehicles With: 307-01A-179
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

9. Separate the transfer plate from the main 11. Remove and discard the intermediate and
control valve body. overdrive accumulator plug seal.
1. Remove the main control valve body.
2. Remove and discard the valve body
separator plate gasket.
3. Remove the valve body separator plate.
4. Remove and discard the valve body
separator plate gasket.
5. Remove the transfer plate.

10. Remove the intermediate and overdrive

accumulator valve plug.
1. Remove the accumulator valve plug
retaining plate.
2. Remove the accumulator valve plug.

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307-01A-180 Automatic Transmission/Transaxle — Vehicles With: 307-01A-180

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

12. CAUTION: Remove, note location and 2. CAUTION: Do not install the
clean one valve at a time to avoid intermediate and overdrive
incorrect installation. accumulator valve plug and seal too
far into the bore and damage the seal.
As necessary, disassemble the parts of
Only push the intermediate and
the accumulator body and main control
overdrive accumulator valve plug until
valve body assemblies.
it is flush with the accumulator body
• Coat the components as quickly as assembly.
possible with automatic transmission fluid
and reassemble them to prevent damage Install the intermediate and overdrive
or incorrect installation. accumulator plug assembly.
1. Install the accumulator valve plug.
2. Install the accumulator valve plug retaining
Assembly plate.
1. WARNING: Wear protective safety
goggles when cleaning components
with compressed air.
CAUTION: If the valve sticks in its bore
and cannot be freed, install a new main
control valve body.
NOTE: Clean the main control valve body and
accumulator body assembly of the main control in
cleaning solvent. Blow dry with moisture-free
regulated compressed air. The solenoid valve
body should not be cleaned in cleaning solvent. It
may be blown clean with compressed air or
wiped clean with a lint-free cloth.
Install a new intermediate and overdrive 3. Install the special tool.
accumulator plug seal and coat with petro-
leum jelly.

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307-01A-181 Automatic Transmission/Transaxle — Vehicles With: 307-01A-181
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. Using the special tool, install the valve 6. Using the special tool, install the
body separator plate gaskets and valve accumulator body separator plate and
body separator plate. gaskets.
1. Install a new valve body separator plate 1. Install a new accumulator body separator
gasket. plate gasket.
2. Install the valve body separator plate. 2. Install the accumulator body separator
3. Install a new valve body separator plate plate.
gasket. 3. Install a new accumulator body separator
plate gasket.

5. Using the special tool, install the main

control valve body. 7. Using the special tool, install the accumu-
lator body assembly.

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307-01A-182 Automatic Transmission/Transaxle — Vehicles With: 307-01A-182

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8. Install the accumulator body transfer plate 11. Install the pressure tap plate and retain-
retaining bolts. ing bolts.
• Tighten the centre bolt first.

12. NOTE: Match the solenoid valve body gasket

9. Install the main control valve body to to passages.
transfer plate retaining bolts. Install the solenoid valve body.
1. Install the manual valve detent spring. 1. Install the solenoid valve body gasket.
2. Install the control valve body to transfer 2. Install the solenoid valve body.
plate bolts.
3. Install the two solenoid valve body
• Tighten with the centre bolt first. retaining bolts.
• Remove the special tool.

10. Install a new pressure tap plate gasket.

13. Install the manual valve.

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307-01A-183 Automatic Transmission/Transaxle — Vehicles With: 307-01A-183
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

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307-01A-184 Automatic Transmission/Transaxle — Vehicles With: 307-01A-184
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Transaxle Case

Disassembly
Special Tool(s)
1. Remove and discard the final drive lubrica-
Remover, O-Ring tion tube.
100-010 (17-063)

Remover/Installer, Bushing,
Lower Arm
204-058 (14-027)

Installer, Bearing Cup, Pinion

205-074 (15-035)

2. Using the special tool, remove and discard

the final drive lubrication tube seal.
Remover/Installer Pivot
Bushing
205-297 (15-086)

Remover/Installer, Needle
Bearing
307-286 (17-064)

Installer, Oil Fill Pipe

307-307 (17-065)
3. Remove the parking pawl ratcheting
spring.

Installer, Bushing/Oil Seal,

Transmission Extension
308-045 (16-015)

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307-01A-185 Automatic Transmission/Transaxle — Vehicles With: 307-01A-185
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. Remove the manual control lever assem- 7. Remove the parking pawl shaft.
bly.

8. Remove the parking pawl assembly.

5. Remove the selector lever assembly. 1. Remove the parking pawl.
1. Remove the nut. 2. Remove the parking pawl return spring.
2. Remove the cam plate.
3. Remove the drive plate.
4. Remove the selector lever shaft.

9. CAUTION: Do not damage the

transaxle case bore during seal
removal.
6. Remove selector lever shaft retaining bolt Remove and discard the manual control
and bracket. lever seal.

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307-01A-186 Automatic Transmission/Transaxle — Vehicles With: 307-01A-186

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

10. Remove the manual valve actuator rod (Z- 12. Remove the manual valve detent lever
link). and shaft assembly.
1. Remove the manual valve detent lever and
manual valve detent lever shaft from the
transaxle case.
2. Remove the manual valve detent lever
from the transaxle case.

11. CAUTION: Do not damage the

transaxle case sealing surface.
NOTE: There are two retaining pins, one on
either side of the manual valve detent lever.
Remove and discard the manual valve
detent lever assembly retaining pins. 13. CAUTION: Do not damage seal bore
1. Remove the detent lever retaining pin. in the transaxle case during seal
removal.
2. Remove the detent lever shaft retaining
pin. Remove and discard the manual control
seal.

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307-01A-187 Automatic Transmission/Transaxle — Vehicles With: 307-01A-187
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

14. Remove the line pressure port plug. 16. NOTE: The driven sprocket bearing No. 18
can only be replaced once. Should the bearing
have been replaced previously a new
transaxle case must be used.
As necessary, remove the No. 18 driven
sprocket bearing assembly from
transaxle case.
1. Install the special tool at the inner side of
the transaxle case.
2. Install the special tool at the outer side of
the transaxle case.

15. Remove and discard the cooler tube

adaptor.

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307-01A-188 Automatic Transmission/Transaxle — Vehicles With: 307-01A-188

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

17. WARNING: Eye protection should be

worn when cleaning components with
compressed air. Failure to follow
these instructions may result in
personal injury.
Clean all components with a suitable
solvent and use moisture-free
compressed air to dry all parts and clean
fluid passages. Check the following
before assembling:
• Final drive lubrication tube for damage
• Manual control linkage for damage or wear
• Case mating surfaces for nicks or
deformation 2. Install the fluid tube adaptor.
• Bearing wear • Install a new seal if necessary.
• Support area wear

Assembly
1. CAUTION: Do not lubricate the outer
surface of the No. 18 driven sprocket
bearing assembly.
NOTE: A new driven sprocket bearing No. 18 can
be installed once before an installation of the
transaxle case becomes necessary. If the No. 18
driven sprocket bearing has been installed
previously and requires a second installation a
new transaxle case must be installed.
NOTE: The No. 18 driven sprocket bearing must 3. Install the line pressure port plug.
be installed with the lettering on the needle
bearing surface facing towards the Needle
Bearing Replacer.
Using the special tools, install the No.18
driven sprocket bearing assembly by
pressing it into the transaxle case.
1. Position the special tool.
2. Position the special tool.
3. Install the No. 18 driven sprocket bearing.

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307-01A-189 Automatic Transmission/Transaxle — Vehicles With: 307-01A-189
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. Using the special tool, install a new man- 6. CAUTION: Do not allow the manual
ual valve seal. shaft retaining pin to contact the
transaxle case.
Install new retaining pins for the manual
valve detent lever assembly.
1. Install the detent lever shaft retaining pin.
2. Install the detent lever retaining pin.
• Verify the manual valve detent lever shaft
rotates without binding.

5. Install the manual valve detent lever

assembly, and the manual valve detent
lever shaft assembly.
1. Install the manual valve detent lever into
the transaxle case.
2. Install the manual valve detent lever shaft
into the transaxle case and lever.
7. Install the manual valve actuator rod (Z-
link).

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307-01A-190 Automatic Transmission/Transaxle — Vehicles With: 307-01A-190

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8. Install the parking pawl assembly. 11. Using the special tool, install a new man-
1. Install the parking pawl return spring. ual control lever seal.
2. Install the parking pawl.

12. NOTE: Lubricate the manual control lever

inner shaft prior to installation.
9. Install the parking pawl shaft.
Install the manual control lever shaft
assembly.
1. Install the selector lever shaft upwards.
2. Install the drive plate.
3. Install the cam plate.
4. Install the nut.

10. Install the parking pawl shaft retainer and

bolt.

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307-01A-191 Automatic Transmission/Transaxle — Vehicles With: 307-01A-191
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

13. NOTE: Verify that the actuating cam rotates 16. Install the final drive lubrication tube into
freely. the seal.
Install the parking pawl ratcheting spring.

17. Using the special tool, install the final

drive lubrication tube into the transaxle
14. NOTE: Do not tighten the manual control at
case.
this stage.
Install the manual control lever assembly
and bolt.

15. Using the special tool, install a new final

drive lubrication tube seal.

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307-01A-192 Automatic Transmission/Transaxle — Vehicles With: 307-01A-192
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Pump Assembly
Special Tool(s)
Gauge Bar, Shim Selection
Special Tool(s) 307-300 (17-055)
Preload Gauge
205-067 (15-041)

Depth Gauge, Shim

Selection
307-300-02 (17-055-02)
Guide Studs
307-127 (17-026)

Name Specification
Automatic transmission fluid ESP-M2C166-H

Disassembly

Item Part Description

Item Part Description Number
Number
2 – Pump seal O-ring
1 – Front pump body

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307-01A-193 Automatic Transmission/Transaxle — Vehicles With: 307-01A-193
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

Item Part Description 3. Separate the pump support and body
Number assembly.
1. Remove the pump support.
3 – Pump driven gear
2. Remove the pump body separator plate
4 – Pump drive gear gasket.
5 – Pump drive gear insert 3. Remove the pump body separator plate.
4. Remove the pump body.
6 – Pump body separator plate
7 – Pump body separator plate
gasket
8 – Front pump support
9 – Front pump seals
1. Remove and discard the seven pump sup-
port seal rings from the pump support.

4. Remove and discard the pump seal.

2. Remove the six pump support bolts.

5. Remove the pump drive gear assembly.

1. Remove the pump drive gear insert.
2. Remove the pump drive gear.
3. Remove the pump driven gear.

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307-01A-194 Automatic Transmission/Transaxle — Vehicles With: 307-01A-194

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

Assembly
6. WARNING: Wear protective safety
goggles when cleaning components 1. NOTE: The identification mark on the pump
with compressed air. driven gear must be facing downward.
Thoroughly clean all components and Install the pump driven gear.
blow them dry with completely dry,
regulated compressed air.
7. Inspect the pump body and gears for
damage and wear.
• Inspect the driven gear teeth.
• Inspect the drive gear teeth.
• Inspect the gear bore.
• Inspect the crescent.
• Inspect the lubrication passages.
8. Inspect the pump support apply circuit
passages and lubrication passages.
1. Inspect the rear lubrication circuit.
2. Inspect the reverse clutch circuit.
3. Inspect the direct clutch circuit. 2. Install the pump drive gear assembly.
4. Inspect the forward clutch circuit. 1. Install the pump drive gear.
5. Inspect the coast clutch circuit. 2. Install the pump drive gear insert.
6. Inspect the converter clutch bypass circuit.

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307-01A-195 Automatic Transmission/Transaxle — Vehicles With: 307-01A-195
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Using the special tool, measure the 5. Align the pump support assembly.
clearance between each gear and the • Fill the pump gear cavity with automatic
pump body face. transmission fluid to the top of the gears.
• If the clearance exceeds specification, in- • Align the pump guide screws.
stall a new pump assembly.
1. Install the pump body.
2. Install the pump body separator plate.
3. Install the pump body separator plate
gasket onto the pump body.
4. Install the pump support.

4. Install the special tool.

6. NOTE: Install the four pump support bolts in

the pump support holes, and remove the guide
studs. Then install the last two bolts.
Install the six pump support bolts.

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307-01A-196 Automatic Transmission/Transaxle — Vehicles With: 307-01A-196

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

9. Measure the pump rotational torque.
7. NOTE: Make sure that the white stripe on the
pump seal is visible around the pump body 1. Install the pump drive shaft.
circumference. 2. Measure the pump rotational torque.
Install the pump seal on the pump body. • Remove the pump drive shaft.
• If rotational torque exceeds the specifica-
tion, disassemble and inspect the pump
assembly for contamination or incorrect
end clearance.

8. NOTE: Make sure the pump support seal rings

are overlapped correctly.
Install the seven pump support seal rings.
10. Install the No.1 pump support thrust
bearing.
• Lubricate the seal rings with automatic
transmission fluid.

11. Install the forward, coast and direct

clutch cylinder and reverse clutch drum
on the pump support.

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307-01A-197 Automatic Transmission/Transaxle — Vehicles With: 307-01A-197
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

12. WARNING: Wear protective safety

goggles when cleaning components
with compressed air.
NOTE: With each application of air, you should
hear the operation of the clutch pack. A hissing or
high pitched squeal indicates that a seal is
damaged or torn. Inspect to find the source and
repair as necessary.
Check the following passages of the
forward, coast and direct clutch cylinder
and reverse clutch drum with moisture -
free compressed air, regulated to 276 kPa
(40 psi).
1. Check the reverse clutch passage.
2. Check the forward clutch passage.
3. Check the direct clutch passage.
4. Check the coast clutch passage.
5. Check the fluid line from the torque con-
verter lock-up clutch bypass.

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307-01A-198 Automatic Transmission/Transaxle — Vehicles With: 307-01A-198
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Reverse Clutch
Special Tool(s)
Protector, Piston Seal
Special Tool(s) 307-276 (17-060-02)
Compressor, Clutch Spring
307-015 (17-058)

Name Specification
Automatic Transmis- GSPM-2C166-H
sion Fluid

Item Part Description

Item Part Description Number
Number
5 Reverse clutch internal
1 Reverse clutch hub retaining spline clutch plates (friction)
ring
6 Reverse clutch external
2 Reverse clutch hub spline clutch plates (steel)
3 Reverse clutch pressure 7 Retaining ring
plate retaining ring
8 Reverse clutch return spring
4 Reverse clutch pressure assembly
plate
9 Reverse clutch piston as-
sembly

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307-01A-199 Automatic Transmission/Transaxle — Vehicles With: 307-01A-199
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

Item Part Description 2. Remove the reverse clutch plates.
Number 1. Remove the pressure plate.
10 Reverse clutch drum as- 2. Remove the friction plates.
sembly 3. Remove the steel plates.
• Inspect for damage or wear.

Disassembly
1. Remove the reverse clutch pressure plate
retaining ring.

3. WARNING: Careless handling of the

special tool can cause personal injury.
CAUTION: Do not fully compress the
reverse clutch return springs.
Remove the retaining ring.
• Using the special tool, compress the re-
verse clutch return springs.

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307-01A-200 Automatic Transmission/Transaxle — Vehicles With: 307-01A-200

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

7. Inspect the parts for damage and wear:
4. Remove the reverse clutch return spring
assembly. • Inspect the clutch plates.
• Inspect the piston and seals.
• Inspect the bushings.
• Inspect the check ball in drum.
• Inspect the drum outer surface band
contact area.
• Inspect the piston bore.

Assembly
1. Soak the internal spline clutch plates in
clean transmission fluid for 15 minutes
before assembly.
2. Using the special tool, install the new re-
5. Remove and discard the reverse clutch verse clutch piston assembly with integral
piston assembly with its integral seals. seals.

6. WARNING: Wear protective safety 3. Install the reverse clutch return spring as-
goggles when cleaning components sembly.
with compressed air.
NOTE: Do not clean the clutch plates in a vapor
degreaser or with any other type of detergent
solution. Clean all parts thoroughly in a clean
solvent and blow dry with moisture-free regulated
compressed air.
Clean the friction plates with a lint-free
cloth.

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307-01A-201 Automatic Transmission/Transaxle — Vehicles With: 307-01A-201
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. CAUTION: Do not fully compress the 6. NOTE: The retaining rings are available in
reverse clutch return springs. various thicknesses.
Install the reverse clutch retaining ring. Install the reverse clutch pressure plate
retaining ring (selective fit).
• Using the special tool, compress the re-
verse clutch return springs.

7. Measure the clearance between the

reverse clutch pressure plate and the
5. Install the reverse clutches.
reverse clutch pressure plate retaining
1. Install the steel plates. ring with a feeler gauge.
2. Install the friction plates. • Repeat the measurement on the opposite
3. Install the pressure plate. side.
• Average the two measurements to
calculate the clearance.
• If the clearance is not within the
specifications, select and install the correct
thickness retaining ring to obtain the
specified clearance.
• Retaining ring sizes:
• 1.39-1.49 mm
• 1.53-1.63 mm
• 1.68-1.78 mm

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307-01A-202 Automatic Transmission/Transaxle — Vehicles With: 307-01A-202
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Planetary Gearsets and Chain Drive Parts

1. Inspect the low and intermediate sun gear

3. Inspect the low and intermediate carrier
assembly for damage.
assembly end play.
• Inspect the gear teeth.
• Use a feeler gauge to measure the end
• Inspect the thrust bearing surfaces. play.
• Inspect the journal surface. • If the end play is out of specification in-
stall a new assembly.

2. Inspect the low and intermediate carrier

assembly. 4. Inspect the low and intermediate ring gear.
• Inspect the pinion gear teeth. • Inspect the gear teeth.
• Inspect the spline teeth. • Inspect the spline teeth.
• Inspect the pinion gear surfaces. • Inspect the thrust bearing surfaces.
• Inspect the bushing surfaces. • Inspect the journal surface.
• Inspect the pinion gear bearings. • Inspect the lug teeth.

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307-01A-203 Automatic Transmission/Transaxle — Vehicles With: 307-01A-203
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

5. Inspect the reverse/overdrive sun gear and 7. Inspect the reverse/overdrive carrier
shell assembly for damage or wear. assembly end play.
• Inspect the gear teeth. • Use feeler gauge to measure the end play.
• Inspect the lug teeth. • If the end play is out of specification in-
• Inspect the thrust bearing surfaces. stall a new assembly.
• Inspect the bushing surface.

8. Inspect the reverse/overdrive ring gear.

• Inspect the gear teeth.
6. Inspect the reverse/overdrive carrier
assembly. • Inspect the spline teeth.
• Inspect the pinion gear teeth. • Inspect the drive sprocket teeth.
• Inspect the clutch plate spline teeth. • Inspect the thrust bearing surfaces.
• Inspect the pinion gear bearings. • Inspect the journal surface.
• Inspect the thrust bearing surfaces. • Inspect the bearings.
• Inspect the bushing surfaces.
• Inspect the No. 8 thrust bearing captured
between the pinions and carrier.

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307-01A-204 Automatic Transmission/Transaxle — Vehicles With: 307-01A-204

4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

9. Inspect the driven sprocket assembly. 11. Inspect the final drive ring gear teeth.
• Inspect the gear teeth.
• Inspect the parking gear lug teeth.
• Inspect the driven sprocket teeth.
• Inspect the thrust bearing surfaces.
• Inspect the bearing surfaces.
• Inspect the rivets.
• Inspect the bushing surfaces.
• Inspect the lubrication holes.

10. Inspect the drive chain.

• Check the drive chain for wear, stretching,
and tightness of the chain links.
• The chain must move freely.

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307-01A-205 Automatic Transmission/Transaxle — Vehicles With: 307-01A-205
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Torque Converter One-Way Clutch Check

Special Tool(s)
Remover, O-ring
100-010 (17-063)

1. NOTE: If leakage or failures are detected

during the test, install a new torque converter.
NOTE: The one-way clutch should only turn anti-
clockwise.
Using the special tool lock the stator.
• Try to rotate the one-way clutch. If the one-
way clutch rotates in a clockwise direction,
discard the torque converter.

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307-01A-206 Automatic Transmission/Transaxle — Vehicles With: 307-01A-206
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Torque Converter Cleaning and Inspection

1. When a new torque converter is installed 4. NOTE: If leaks or damage is detected during
the following actions must be carried out. inspection, a new torque converter should be
• All cooler lines must be thoroughly cleaned installed.
by back and forward flushing. For
Check seal contact surface on the impeller
additional information, refer to
hub of torque converter for excessive wear
Transmission Fluid Cooler - Backflushing or scoring.
and Cleaning in this section.
• All coolers (in-tank and auxiliary) must be
thoroughly cleaned by back and forward
flushing. For additional information, refer
to Transmission Fluid Cooler in this
section.
• If the transmission cooling system fails the
flow test, new coolers or lines must be
installed. If new cooler lines are to be
installed refer to Transmission Cooling. For
additional information, refer to
Transmission Fluid Cooler Tubes in this
section. If new coolers are to be installed,
use only factory approved service parts
and refer to Engine Cooling. For additional
information, refer to Section 303-03. 5. Inspect the torque converter studs for
damage.
2. If a new torque converter is not being
installed, the following must be carried
out.:
• Thoroughly clean the torque converter. For
additional information, refer to Torque
Converter Flushing in this section.
• All cooler lines must be thoroughly cleaned
by back and forward flushing. For
additional information, refer to
Transmission Fluid Cooler - Backflushing
and Cleaning in this section.
• All coolers (in-tank and auxiliary) must be
thoroughly cleaned by back and forward
flushing. For additional information, refer
to Transmission Fluid Cooler -
Backflushing and Cleaning in this section.
• Carry out transmission cooler flow test as
outlined in this section. If the transmission
cooling system fails the flow test, new
coolers or lines must be installed. If new
cooler lines are to be installed, refer to
Transmission Cooling. For additional
information, refer to Section 307-02A / 307-
02B. If new coolers are to be installed, use
only factory approved service parts and
refer to Engine Cooling. For additional
information, refer to Section 303-03.
3. Carry out all torque converter checks
listed in this section.

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307-01A-207 Automatic Transmission/Transaxle — Vehicles With: 307-01A-207
4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Torque Converter Flushing

Name Specification
Automatic transmission ESP-M2C166-H
fluid

1. CAUTION: Mineral spirits used to clean

the torque converter must be fresh,
non-chlorinated and non-halogenated.
Do not use water based solvents or
damage to the transaxle or torque
converter may occur. If local
ordinances state that water based
solvent must be used, then for this
procedure use clean automatic
transmission fluid recommend for this
transaxle.
Partially fill the torque converter using
automatic transmission fluid.
2. Hand agitate the torque converter then
thoroughly drain the fluid.
3. Repeat this procedure until the torque
converter is clean.
4. After flushing drain the remainder of the
solvent.
5. Add 1.9 litre of clean automatic
transmission fluid and agitate by hand.
6. Thoroughly drain the torque converter.
7. Refill the torque converter automatic
transmission fluid.
8. Iinstall the torque converter.

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307-01A-208 Automatic Transmission/Transaxle — Vehicles With: 307-01A-208
4-Speed Automatic Transaxle

ASSEMBLY
Transaxle (17 214 8)
ASSEMBLY

Special Tool(s)
Gauge Bar, Shim Selection
Special Tool(s) 307-300 (17-055)
Remover and Installer, Lower
Arm Bushing
204-168 (14-043)
Adapter for 307-300
307-300-01 (17-055-01)
Installer, Drive Pinion Oil
Seal
205-077 (15-047A)
Depth Gauge, Shim
Selection
307-300-02 (17-055-02)
Installer, Shift Shaft Oil Seal
307-050 (17-008)

Plate, Transmission Air Test

307–301 (17–056)
Installer, Torque Converter
Oil Seal
307-273 (17-052)
Preload Plate, Shim
Selection
307-304 (17-057)
Protector, Piston Seal
307-275 (17-060-01)

Adapter for 307-304

307-304-01 (17-057-01)
Alignment Pins, Valve Body
307-299 (17054)

Adapter for 307-304

307-304-02 (17-057-02)
Aligner, Selector Shaft
307-S290 (17066)

Adapter for 307-304

307-304-03 (17-057-03)
Rod Selector, Servo Piston
307-S296 (17-059)

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307-01A-209 Automatic Transmission/Transaxle — Vehicles With: 307-01A-209
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
Special Tool(s) Assembly
Alignment Gauge, TRS 1. Prepare the transaxle for assembly by
307-351 (17-090) proceeding the following steps:
• Clean all parts (except the friction plates,
seals, and intermediate and overdrive
band) in solvent.
• Dry all parts with moisture-free regulated
Name Specification compressed air (do not use shop towels).
• Lubricate all internal parts (including friction
Automatic transmission fluid ESP-M2C166-H plates) with automatic transmission fluid.
Permanent thread sealer • Order the required repair parts.
Petroleum jelly • Make sure the complete assortment of
selective thickness parts are available for
adjustments during assembly:
• Drive sprocket thrust washers
• Driven sprocket thrust bearing shims
• Differential case thrust bearing shims
• Low and reverse clutch pressure plates
• During assembly, use petroleum jelly to
hold the parts in position (do not use
grease).
• When tightening retaining bolts or nuts, use
an accurate torque wrench.
• Lightly coat bolt and nut threads with
automatic transmission fluid before
installation.
2. Install intermediate and overdrive band
assembly into the transaxle case.

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307-01A-210 Automatic Transmission/Transaxle — Vehicles With: 307-01A-210

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
3. NOTE: Lubricate the seal rings with clean
6. NOTE: Coat the low and reverse clutch piston
automatic transmission fluid.
oil seals and the piston bore with clean
Install the No. 1 pump support thrust bear- automatic transmission fluid.
ing.
Install a new low and reverse clutch piston
outer seal.

4. NOTE: Apply a thin coat of petroleum jelly to

the pump support seals and to the pump bore
7. NOTE: Coat the low and reverse clutch piston
in the transaxle.
oil seals and the piston bore with clean
Install pump assembly into the transaxle automatic transmission fluid.
case.
Install a new low and reverse clutch piston
inner seal.

5. NOTE: Tighten the retaining bolts in the

sequence shown.
Install the pump assembly bolts.

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307-01A-211 Automatic Transmission/Transaxle — Vehicles With: 307-01A-211
4-Speed Automatic Transaxle

ASSEMBLY (Continued)

8. Using the special tool, install the low and 11. CAUTION: The low and reverse clutch
reverse clutch piston. wave spring is installed at this stage
• Lubricate seals and piston bore with clean for measurement purposes only.
automatic transmission fluid.
Install the low and reverse clutch wave
spring.

9. Install the low and reverse clutch return

spring assembly.
12. Install the low/reverse clutch plates.
1. The low/reverse clutch external splined
(steel) clutch plates.
2. The low/reverse clutch internal splined
(friction) clutch plates.
3. The thin, eight wave low/reverse clutch
cushion spring.
4. The low/reverse clutch plate.

10. Install the low and reverse clutch return

spring retaining ring.

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307-01A-212 Automatic Transmission/Transaxle — Vehicles With: 307-01A-212

4-Speed Automatic Transaxle

ASSEMBLY (Continued)

13. CAUTION: The low one-way clutch 14. Measure the play between the low and
thrust plate is installed at this stage reverse clutch pressure plate and the
for measurement purposes only. thrust washer of the low one-way clutch
(three-plate clutch).
Install the low one-way clutch thrust
• Repeat the measurement on the opposite
plate.
side.
• Average the two measurements to
calculate the clearance.
• If the clearance is not within specification,
select and fit the correct thickness pressure
plate to obtain the specified clearance.
• Pressure plate thicknesses:
• 2.57-2.46 mm
• 2.36-2.26 mm
• 2.16-2.06 mm

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307-01A-213 Automatic Transmission/Transaxle — Vehicles With: 307-01A-213
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
15. Measure the play between the low and 16. NOTE: One tooth of the low and reverse
reverse clutch pressure plate and the clutch pressure plate is notched for
thrust washer of the low one-way clutch identification.
(two-plate clutch).
Remove the low one-way and low and
• Repeat the measurement on the opposite reverse clutch plates.
side.
1. The low one-way clutch thrust plate.
• Average the two measurements to
2. The low/reverse clutch external splined
calculate the clearance.
(steel) clutch plates.
• If the clearance is not within specification,
3. The low/reverse clutch internal splined
select and fit the correct thickness pressure
(friction) clutch plates.
plate to obtain the specified clearance.
4. The thin, eight wave low/reverse clutch
• Pressure plate thicknesses:
cushion spring.
• 2.57-2.46 mm
5. The low/reverse clutch plate.
• 2.36-2.26 mm
• 2.16-2.06 mm

17. Install the No. 1 pump support thrust

bearing assembly.

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307-01A-214 Automatic Transmission/Transaxle — Vehicles With: 307-01A-214

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
18. NOTE: Remove Seal Sizer from forward, 21. NOTE: It is essential that the installation
coast and direct clutch cylinder. depth of the sun gear is maintained.
Install the forward, coast and direct Install the forward one-way clutch and
clutch cylinder assembly and reverse low-intermediate sun gear assembly.
clutch drum assembly. • Measure the sun gear clearance.

19. Install the turbine shaft. 22. Install the No. 5 low-intermediate sun
gear thrust bearing.

20. Install the No. 4 turbine shaft thrust bear-

ing. 23. Install the low-intermediate carrier as-
sembly.

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307-01A-215 Automatic Transmission/Transaxle — Vehicles With: 307-01A-215
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
24. Install the No. 6 low-intermediate carrier 27. Install the reverse and overdrive sun gear
thrust bearing. and shell assembly.

25. Install the low-intermediate ring gear as- 28. Install the reverse and overdrive carrier
sembly. assembly with the captured No. 8 thrust
bearing.

26. Install the No. 7 reverse and overdrive

sun gear thrust bearing. 29. Install the thick, ten-wave low/reverse
clutch wave spring.

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307-01A-216 Automatic Transmission/Transaxle — Vehicles With: 307-01A-216

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
30. Install the low and reverse clutch plates.
33. Install the low one-way clutch thrust
1. Install the external spline (steel) clutch plate.
plates.
2. Install the clutch internal spline (friction)
clutch plates.
3. Install the clutch pressure plate previously
selected.

34. NOTE: Make sure to position the low one-

way clutch retaining ring as shown.
Install the low one-way clutch retaining
ring.
31. Install the thin, eight wave low and re-
verse clutch wave spring.

35. Install the manual valve detent lever

actuating rod assembly.
• Install the parking cam actuator lever.
32. Install the low one-way clutch assembly
with the identification ring on the inner
ring facing upward.

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307-01A-217 Automatic Transmission/Transaxle — Vehicles With: 307-01A-217
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
36. Install the manual valve detent lever. 38. Install the special tool with short spacers.

37. Install the special tools. 39. Zero the Vernier calipers.
1. Position the measuring calipers on the
measuring bar (or measuring plate) and
slide down the depth gauge as far as
possible.
2. Zero the depth gauge.

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307-01A-218 Automatic Transmission/Transaxle — Vehicles With: 307-01A-218

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
40. Using the special tools, measure the 42. Determine the thickness of the driven
depth of the bearing thrust surface from sprocket adjustment shim (No. 11).
the measuring bar. • "A" - "B" = "C"
• Lay the measuring bar with the spacer • Dimension "A" = measured distance
shims on the housing. • Dimension "B" = measured distance
• Measure and note the distance between
• Dimension "C" = thickness of adjustment
the measuring bar and the bearing thrust
shim.
surface, measurement ""A”.
• The adjustment shim is available in
different thicknesses:
• Measured axial clearance shim that should
be fitted
• 14.34mm - 14.17mm – 2.20mm - 2.10mm
• 14.16mm - 14.00mm – 2.02mm - 1.92mm
• 13.99mm - 13.83mm – 1.8mm - 1.75mm
• 13.82mm - 13.66mm – 1.67mm - 1.57mm
• 13.65mm - 13.49mm – 1.50mm - 1.40mm
• 13.48mm - 13.32mm – 1.32mm - 1.22mm
43. Install and lubricate with automatic
transmission fluid the following:
1. The needles and seals in the No. 18 driven
41. Using the special tools, measure the sprocket bearing.
depth of the reverse and the 4th gear 2. Install the selected No. 11 driven sprocket
planet carrier shim.
• Repeat the measurement at the opposite 3. Install the No. 12 driven sprocket bearing.
side and calculate the average value,
measurement "B”.
• Remove the special tools.

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4-Speed Automatic Transaxle

ASSEMBLY (Continued)
44. Install the No. 9 reverse and overdrive 46. Install the special tools.
ring gear thrust bearing.

45. NOTE: Installation of the reverse and

overdrive ring gear assembly at this stage is
for measurement purposes only.
Install the reverse and overdrive ring
gear assembly.

47. Install the special tool with short spacers.

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307-01A-220 Automatic Transmission/Transaxle — Vehicles With: 307-01A-220

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
48. Calculate the thrust washer for the drive 50. Determine the thickness of the drive gear
gear. thrust washer.
• Add the thickness of the measuring bar • "A" - "B" = "C"
and the height of the short spacer sleeves, • Dimension "A" = (thickness of measuring
measurement ""A”. bar)+ (height of spacer sleeves)
49. NOTE: Zero the measuring tip on the • Dimension "B" = measured distance
measuring bar. • Dimension "C" = thickness of thrust washer
Using the special tools, measure the • The thrust washer is available in different
depth of drive gear thrust washer from thicknesses: (measured in mm):
the measuring bar, and note the reading.
• Measured size washer that should be fitted
• Repeat the measurement at the opposite (color code)
side and calculate the average value,
• 1.12mm - 0.86mm – 1.51mm -1.41mm
measurement "B”.
(blue)
• Remove the special tools and the drive
• 0.85mm - 0.60mm – 1.67mm (black)
gear.
• 0.59mm - 0.34mm – 2.03mm - 1.93mm
(grey)
• 0.33mm - 0.08mm – 2.29mm - 2.19mm
(green)
51. Install the selected No. 10 drive sprocket
thrust washer on the torque converter
housing.
• Coat the No.10 drive sprocket thrust
washer with petroleum jelly.

52. Install the reverse and overdrive ring

gear assembly.

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307-01A-221 Automatic Transmission/Transaxle — Vehicles With: 307-01A-221
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
55. Install the chain pan in the transaxle
53. Install the filter and seal assembly.
case.

54. NOTE: Lubricate the filter recirculating

regulator return pipe with automatic 56. WARNING: Wear gloves as protection
transmission fluid prior to installation. from sharp chain and sprocket teeth.
Failure to follow this instruction may
Using the special tools, install a new filter result in personal injury.
recirculation regulator return pipe.
Assemble and install the drive chain
1. Install the special tool in the filter eyelet
assembly.
and transaxle hole.
1. Drive chain (copper colored link facing
2. Using the special tool, install the return
upward).
pipe seal.
2. Driven sprocket assembly.
• Remove the special tool.
3. Reverse and overdrive ring gear assembly.
• Verify that the driven sprocket assembly
and reverse and overdrive ring gear as-
sembly are fully installed.

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307-01A-222 Automatic Transmission/Transaxle — Vehicles With: 307-01A-222

4-Speed Automatic Transaxle

ASSEMBLY (Continued)

57. Install the chain pan cover. 60. CAUTION: Use plastic washers
between bolt heads and special tool.
Install the special tools.
1. Install the special tool.
2. Install the special tool and bolts.

58. Install the No. 13 driven sprocket thrust

bearing.

61. Using the special tools, measure the

distance between the measuring bar and
the bearing thrust surface.
• Repeat the measurement at the opposite
side and calculate the average value,
measurement "B”.
• Remove the special tools.

59. Install the final drive carrier and differen-

tial assembly.

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307-01A-223 Automatic Transmission/Transaxle — Vehicles With: 307-01A-223
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
62. NOTE: "A” is a predefined dimension of 177.8 64. NOTE: Check for correct alignment of the
mm. lube tube on the converter housing.
Calculate the shim thickness (measuring Install the torque converter housing onto
bar and spacer sleeve). the transaxle case.
• "A" - "B" = "C" • Install a new split flange gasket.
• Dimension "A" = 177.8 mm
• Dimension "B" = measured distance
• Dimension "C" = thickness of shim
• The adjustment shim is available in
different thicknesses (measured in mm):
• Measured axial clearance -> shim that
should be fitted
• 130.76mm - 130.46mm – 1.08mm -
0.98mm
• 130.45mm - 130.16mm – 1.38mm -
1.28mm
• 130.15mm - 129.87mm – 1.67mm -
1.57mm
• 129.86mm - 129.57mm – 1.97mm - 65. NOTE: Tighten the torque converter housing
1.87mm retaining bolts in the sequence shown.
• 129.56mm - 129.27mm – 2.27mm - Install the torque converter housing to
2.17mm transaxle case bolts.
63. Install the differential shim and
differential bearing assembly.
1. Install the No. 14 differential bearing shim
(selective fit).
2. Install the No. 15 differential bearing.

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307-01A-224 Automatic Transmission/Transaxle — Vehicles With: 307-01A-224

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
66. NOTE: Note the number of grooves on the 68. NOTE: Struts on the special tool fit into the
intermediate and overdrive servo apply rod. servo cover retaining ring groove.
Lubricate the assembly with transmission Assemble the special tool.
fluid before installation. 1. Install struts.
1. Install the servo cover with integral seal. 2. Install bar.
2. Install the damping spring. 3. Install the bolts.
3. Install the servo return spring. 4. Install the center bolt.

67. Install the intermediate and overdrive 69. Using the special tool, measure the
servo piston assembly into the transaxle distance between the center bolt and the
case. special tool securing bar gap.
• Install the special tool. • Record the measurement.

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307-01A-225 Automatic Transmission/Transaxle — Vehicles With: 307-01A-225
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
70. Tighten the center bolt on the special tool 74. Align the servo cover.
until the servo piston no longer moves.

75. WARNING: Servo return spring force

71. Using the special tool, measure the is very high.
distance between the center bolt and the
special tool securing bar. CAUTION: Only compress the servo
• Subtract the previously noted piston until the retainer groove becomes
measurement from this measurement to visible.
calculate the travel. Using the special tools, install the servo
• If the piston travel is not within the cover.
specification, select a new actuating rod for • Install the retaining ring.
the intermediate and overdrive gear servo
piston assembly.
• Repeat the measurement steps if a new
actuating rod is installed.
• Remove the special tool.

72. NOTE: The piston rod and servo piston are

supplied as an assembly.
Calculate the required rod length form
parts available.
• 105,7 mm (two marking rings)
• 107,1 mm (one marking ring)
• 108,1 mm (no marking ring)
73. Install the required servo piston
assembly.

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307-01A-226 Automatic Transmission/Transaxle — Vehicles With: 307-01A-226

4-Speed Automatic Transaxle

ASSEMBLY (Continued)

76. CAUTION: Do not check the coast 77. Install the thermostatic fluid level control
clutch, as this would cause the coast valve.
clutch piston to be pushed out of the 1. Install the thermostatic fluid level control
forward clutch piston. valve.
2. Install the bracket.
CAUTION: Carry out the air pressure test
only with dry compressed air at a 3. Install the thermostatic fluid level control
maximum pressure of 2,75 bar. valve bracket retaining bolt.
NOTE: In the event of leaks first check that the
special tool is correctly attached.
Perform Compressed Air Test.
1. Test the reverse clutch.
2. Test the forward clutch.
3. Test the direct clutch.
4. Test the low and reverse clutch.
5. Test the loosened position of 2nd and 4th
brake band.
6. Test the tightened position of 2nd and 4th
brake band.

78. CAUTION: Do not pull wires or

damage the solenoid body electrical
connector, damage to the connector
and terminals may result.
Install the solenoid body electrical con-
nector O-ring seal and install the electri-
cal connector into its bore in the trans-
axle case.

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307-01A-227 Automatic Transmission/Transaxle — Vehicles With: 307-01A-227
4-Speed Automatic Transaxle

ASSEMBLY (Continued)

79. CAUTION: Handle the main control 80. NOTE: Tighten the main control valve body
valve body with care to prevent retaining bolts in the sequence shown.
manual valve damage. NOTE: Bolts 1, 7 and 9 are longer than the
others.
Connect the manual valve.
1. Lift the main control away from the case. Install the main control valve body bolts.
2. Connect the Z-link to the manual valve.
• Install the solenoid body retaining clip.

81. Loosen the nut on the ball stud for the

manual valve detent lever actuating rod
assembly.

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307-01A-228 Automatic Transmission/Transaxle — Vehicles With: 307-01A-228

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
82. Move the manual control lever shaft to 85. Adjust the shift linkage.
the "D" position. • Tighten the nut on the ball stud.
• Install a pin to hold special tool in place. • Move back to the "D" position to recheck
the adjustment.

83. Move the manual valve detent lever as-

sembly to the "D" position. 86. Using the special tool, recheck the man-
ual control lever assembly setting.

84. Tighten the nut on the ball stud finger

tight. 87. Install the manual control lever.
• Remove the shifter pin from the special 1. Install the manual control lever.
tool.
2. Tighten the manual control lever retaining
bolt.

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307-01A-229 Automatic Transmission/Transaxle — Vehicles With: 307-01A-229
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
88. Rotate the manual valve detent lever 90. NOTE: Tighten the main valve control cover
assembly to the Neutral position. bolts in the sequence shown.
1. Low 1 Install the main valve control cover.
2. Low 2 • Install a new gasket.
3. Drive • Install the main valve control cover bolts.
4. Neutral
5. Reverse
6. Park

89. Using the special tool, install the

transmission range (TR) sensor.
1. Install the special tool.
2. Tighten the sensor bolts.
3. Check the connector for damage.
• Remove the special tool.

91. Install a new transmission filler tube

grommet.

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307-01A-230 Automatic Transmission/Transaxle — Vehicles With: 307-01A-230

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
92. Install the transmission filler tube 94. Using the special tool, install new half-
assembly. shaft oil seals.
1. Install the tube.
2. Install the transmission filler tube retaining
bolt.
• Install the fluid level indicator.

95. NOTE: Make sure the torque converter fluid

seal garter spring does not become dislodged
during installation. If the garter spring does
become dislodged, install a new torque
converter fluid seal.
93. Install the turbine shaft speed (TSS)
sensor. Using the special tool, install a new
• Install a new O-ring seal. torque converter fluid seal.
1. Lubricate the O-ring seal with petroleum • Coat the torque converter fluid seal garter
jelly. spring with petroleum jelly.
2. Install the TSS sensor retaining bolt.

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307-01A-231 Automatic Transmission/Transaxle — Vehicles With: 307-01A-231
4-Speed Automatic Transaxle

ASSEMBLY (Continued)
96. Install the drain plug. 99. NOTE: The torque converter hub must
• Use a new drain plug gasket. engage fully with the oil pump drive gear.
Install the torque converter.

97. Install the output shaft speed (OSS)

sensor with a new O-ring seal. 100. Check the torque converter installation
• Lubricate the O-ring seal with petroleum depth.
jelly. 1. Place a steel rule on the transaxle flange.
2. Check the distance between the transaxle
flange and the torque converter centering
pin.

98. NOTE: Check correct rotation of the pump

drive shaft.
Install the pump drive shaft.

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307-01A-232 Automatic Transmission/Transaxle — Vehicles With: 307-01A-232

4-Speed Automatic Transaxle

ASSEMBLY (Continued)
101. Remove the transaxle from the special
tool.

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307-01A-233 Automatic Transmission/Transaxle — Vehicles With: 307-01A-233
4-Speed Automatic Transaxle

INSTALLATION
Transaxle (17 214 0)
INSTALLATION

Name Specification
Washer E830819S71
Special Tool(s) High-temperature grease ESD-M1C220-A
Alignment Pins, Subframe Automatic transmission fluid ESP-M2C166-H
205-316 (15-097-A)

Support Bar, Engine

303-290A (21-140A)

Adapter for 303-290A

303-290-01 (21-140-03)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Adapter for 303-290A

303-290-05A (21-140-05A)

General Equipment
Securing straps
Transmission jack
Tire lever
Steel straightedge
Auxiliary plugs

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307-01A-234 Automatic Transmission/Transaxle — Vehicles With: 307-01A-234

4-Speed Automatic Transaxle

INSTALLATION (Continued)

2. CAUTION: The torque converter must

Installation remain at the correct installation
depth throughout the entire
All Vehicles installation procedure. Check that the
adapter plate is in the correct position.
1. CAUTION: The torque converter hub
must be engaged fully in the oil pump Using the transmission jack install the
drive gear. transaxle.
NOTE: The locations of engine and transaxle • Make sure the studs on the torque
mountings and engine support insulators are converter are entered into the engine drive
described looking from the transaxle to the plate and loosely install in the transaxle
engine. retaining flange bolts.
• Remove the securing straps.
Check the installation depth of the torque
converter.
1. Lay a steel straightedge across the
automatic transaxle flange.
2. Check the installation depth between the
transaxle flange and the torque converter
centering spigot for the correct clearance.
• Apply a thin layer of high-temperature
grease to the centering spigot bore on the
torque converter.

3. Install the upper transaxle retaining bolts.

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307-01A-235 Automatic Transmission/Transaxle — Vehicles With: 307-01A-235
4-Speed Automatic Transaxle

INSTALLATION (Continued)
4. Install the lower transaxle retaining bolts. 7. Attach the torque converter to the flywheel
with new retaining nuts (four nuts).
• Install the rubber cover.

5. Install the right-hand side transaxle retain-

ing bolts.
8. Lower the vehicle.
9. Install the rear engine and transaxle
mounting bracket.

6. Install the left-hand side transaxle retain-

ing bolts.

10. Install the rear engine mounting.

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4-Speed Automatic Transaxle

INSTALLATION (Continued)
11. Remove the special tools. 14. Connect the automatic transmission
control electrical connector.
• Install the cable ties.
• Attach the wiring harness retaining clip.

12. Install the bulkhead cover.

15. Connect the transmission range (TR)

sensor electrical connector.

13. Install the plastic cover to the hood.

16. Raise and support the vehicle. For

additional information, refer to Section
100-02.
17. Install the starter motor.

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307-01A-237 Automatic Transmission/Transaxle — Vehicles With: 307-01A-237
4-Speed Automatic Transaxle

INSTALLATION (Continued)
18. Install the wiring harness and fluid cooler 20. Connect the turbine shaft speed (TSS)
pipe bracket. sensor electrical connector (colored
• Attach the fluid cooler pipe. white).
• Attach the wiring harness. • Install the wiring retaining clip.

19. CAUTION: Use an open ended 21. CAUTION: Use an open ended
spanner on the fluid line adaptor to spanner on the fluid line adaptor to
prevent it from turning. prevent it from turning.
Attach the fluid cooler pipe to the trans- Attach the fluid cooler pipe to the
axle. transaxle.
• Attach the fluid pipe bracket to the trans-
axle.

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307-01A-238 Automatic Transmission/Transaxle — Vehicles With: 307-01A-238

4-Speed Automatic Transaxle

INSTALLATION (Continued)

22. CAUTION: The inner joint must not be 24. Connect the output shaft speed (OSS)
bent more than 18 degrees, the outer sensor electrical connector (colored
joint must not be bent more than 45 black).
degrees.
Attach the left-hand front drive halfshaft.

Vehicles with Xenon headlamps

25. Connect the headlamp levelling sensor
electrical connector.
23. CAUTION: The inner joint must not be
bent more than 18 degrees, the outer
joint must not be bent more than 45
degrees.
Attach the right-hand front drive halfshaft
and intermediate shaft.
1. Push the intermediate shaft into the output
flange.
2. Install a new centre bearing cap and retain-
ing nuts.

All vehicles
26. Install the accessory drive belt cover.

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307-01A-239 Automatic Transmission/Transaxle — Vehicles With: 307-01A-239
4-Speed Automatic Transaxle

INSTALLATION (Continued)
27. Install the subframe. For additional
information, refer to Section 502-00.
33. CAUTION: Use an Allen key to
28. Install the radiator splash shield.
prevent the piston rod from rotating.
Tighten the suspension top mount nut.

29. Lower the vehicle.

30. Attach the selector lever cable to the
transaxle. 34. Install the strut and spring assembly top
mount brace cover.
1. Install the selector lever cable bracket.
2. Attach the selector lever cable.

35. Install the engine upper cover.

31. Install the air cleaner. For additional
information, refer to Section 303-01A /
303-01B / 303-01C / 303-01D.
32. Refill the transaxle. For additional
information, refer to Transmission Fluid
Drain and Refill in this section.

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307-01A-240 Automatic Transmission/Transaxle — Vehicles With: 307-01A-240

4-Speed Automatic Transaxle

INSTALLATION (Continued)
36. Install the pipes, attach the pipes and
hoses to the engine upper cover.

37. Connect the battery ground cable. For

additional information, refer to Section
414-01.

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307-01B-1 Automatic Transmission/Transaxle 307-01B-1

SECTION 307-01B Automatic

Transmission/Transaxle
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 307-01-3

Gear Ratios ...................................................................................................................... 307-01-3

DESCRIPTION AND OPERATION

Transaxle Description........................................................................................................ 307-01-4

General ............................................................................................................................ 307-01-4
Transmission cross-section .............................................................................................. 307-01-6
Torque converter with TCC............................................................................................... 307-01-8
Oil pump........................................................................................................................... 307-01-9
1. and 2nd planetary gearset ............................................................................................ 307-01-9
Reduction planetary gearset............................................................................................. 307-01-11
Clutches and brakes......................................................................................................... 307-01-13
Differential assembly ........................................................................................................ 307-01-15
Control housing ................................................................................................................ 307-01-17
Identification Tags ............................................................................................................. 307-01-18
Transmission Ranges and Power Flow.............................................................................. 307-01-19
Overview of operation....................................................................................................... 307-01-19
Transmission in 1st gear .................................................................................................. 307-01-19
Power transmission route in first gear.............................................................................. 307-01-21
Transmission in 2nd gear ................................................................................................. 307-01-23
Power transmission route in second gear ......................................................................... 307-01-25
Transmission in 3rd gear .................................................................................................. 307-01-27
Power transmission route in third gear ............................................................................ 307-01-28
Transmission in 4th gear .................................................................................................. 307-01-30
Power transmission route in fourth gear ........................................................................... 307-01-32
Transmission in 5th gear .................................................................................................. 307-01-33
Power transmission route in fifth gear.............................................................................. 307-01-35
Transmission in reverse gear ........................................................................................... 307-01-37
Power transmission route in reverse gear........................................................................ 307-01-38
Transaxle Electronic Control System ................................................................................. 307-01-41
Overview .......................................................................................................................... 307-01-41
Transmission control unit.................................................................................................. 307-01-42
Shift strategy .................................................................................................................... 307-01-43
Electronically synchronised gearshift control .................................................................... 307-01-45
Signal transmission on the CAN databus.......................................................................... 307-01-47
TSS sensor.......................................................................................................... 307-01-49
Intermediate shaft speed sensor ...................................................................................... 307-01-49
OSS sensor ......................................................................................................... 307-01-50
TFT sensor .......................................................................................................... 307-01-50
TR sensor............................................................................................................ 307-01-51
Select-Shift switch ............................................................................................................ 307-01-51
Stoplamp switch ............................................................................................................... 307-01-52
Brake pressure switch ...................................................................................................... 307-01-52
Overview of solenoids in the main control body ................................................................ 307-01-53

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307-01B-2 Automatic Transmission/Transaxle 307-01B-2

Main regulating valve ........................................................................................................ 307-01-54

PWM solenoid - 2nd/4th/5th gear brake ............................................................................ 307-01-54
PWM solenoid - 3rd-5th gear clutch .................................................................................. 307-01-55
PWM solenoid - TCC ........................................................................................................ 307-01-55
Shift solenoids SSA, SSB and SSC .................................................................................. 307-01-56
Shift solenoid - reduction brake band ................................................................................ 307-01-57
Shift solenoid - engagement of neutral.............................................................................. 307-01-57
Selector lever lock solenoid............................................................................................... 307-01-58
Solenoid for the ignition key removal inhibitor ................................................................... 307-01-58
Instrument Cluster............................................................................................................. 307-01-59
GEM..................................................................................................................... 307-01-59
Backup lamp relay ............................................................................................................ 307-01-60

DIAGNOSIS AND TESTING

Diagnostic Trouble Code Charts ........................................................................................ 307-01-61

Diagnostic Strategy ............................................................................................................ 307-01-66
Inspection and Verification ................................................................................................ 307-01-66

GENERAL PROCEDURES

Transmission Fluid Level Check......................................................................................... 307-01-67

Transmission Fluid Drain and Refill .................................................................................... 307-01-69

IN-VEHICLE REPAIR

Fluid Pan, Gasket and Filter............................................................................................... 307-01-70

Halfshaft Seal LH .......................................................................................... (14 303 0) 307-01-74
Halfshaft Seal RH.......................................................................................... (14 304 0) 307-01-77
Transmission Range (TR) Sensor ................................................................. (17 705 0) 307-01-80
Main Control Valve Body.................................................................................................... 307-01-83
Solenoids - Shift, TCC and EPC......................................................................................... 307-01-86
Transmission Control Module (TCM).................................................................................. 307-01-89

REMOVAL AND INSTALLATION

Transaxle — 2.0L Diesel ............................................................................... (17 214 0) 307-01-92

Transaxle — 2.5L.......................................................................................... (17 214 0) 307-01-98

INSTALLATION

Transaxle — 2.0L Diesel ............................................................................... (17 214 0) 307-01-104

Transaxle — 2.5L.......................................................................................... (17 214 0) 307-01-111

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307-01B-3 Automatic Transmission/Transaxle — Vehicles With: 307-01B-3
5-Speed Automatic Transaxle

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Automatic transmission fluid WSS-M2C922-A1
Sealer WSS-M4G320-A3
Grease WSD-M1C230-A

Capacities
Litres
Automatic transmission fluid (2.0L diesel engine) 7.9
Automatic transmission fluid (2.5L V6 engine) 8.8

Gear Ratios
Description Gear Ratio
Fifth gear 3.801
Second gear 2.131
Third gear 1.364
Fourth gear 0.935
Fifth gear 0.685
Reverse gear 2.970
Final drive (2.0L diesel engine) 3.491
Final drive (2.5L V6 engine) 3.712

Torque Specifications
Item Nm lb-ft lb-in
Transmission range (TR) sensor retaining bolt 6 - 53
Transaxle housing to engine retaining bolts 48 35 -
Torque converter retaining nuts 36 27 -
Engine rear mount bracket retaining bolts 80 59 -
Engine rear mount retaining bolts M12 133 98 -
Engine rear mount retaining bolts M10 48 35 -
Ground cable to the transaxle retaining bolt 20 15 -
Cable bracket bolts 10 - 89
Intermediate shaft center bearing cap locknuts 25 18 -
Charge air cooler intake hose retaining bolts 20 15 -
Selector lever cable cover retaining bolts 22 16 -
Strut and spring assembly top mount retaining 30 22 -
nuts
Starter motor retaining bolts 35 26 -
Battery cable to starter motor 12 9 -
Ignition switch to starter motor cable retaining nut 6 - 53
Battery tray support bracket retaining bolts 20 15 -
Ground cables to battery support braket 20 15 -
Central junction box (CJB) to battery tray 10 - 89
Transmission fluid test plug 15 11 -
Transaxle drain plug 45 33 -
Transaxle fluid pan retaining bolts 8 - 71
Fluid cooler pipes to transaxle 40 30 -
Transaxle wiring harness bracket to transaxle re- 9 - 80
taining bolts

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307-01B-4 Automatic Transmission/Transaxle — Vehicles With: 307-01B-4
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transaxle Description
DESCRIPTION AND OPERATION

(currently only available on vehicles with a diesel

engine). This results in improved NVH
General characteristics, reduced fuel consumption and
reduced emissions.
The 5F31J automatic transmission has been
developed by the Japanese automatic The transmission control unit calculates the
transmission manufacturer Jatco gearshift timing according to the personal driving
TransTechnology. style of the driver. The current driving resistance,
such resistance due to towing a trailer or driving
5F31J stands for:
uphill/downhill in mountains or steep hills, is also
• 5- 5 forward drive gears taken into account when calculating the gearshift
• F- front-wheel drive timing.
• 31- maximum input torque of 310 Nm Gears can be selected either automatically
• J- Jatco TransTechnology (selector lever position "D") or by the driver
(Select-Shift-Mode). The transmission range or
The transmission is fully-automatic and
selected gear (Select-Shift-Mode) is indicated to
electronically controlled.
the driver in the instrument panel.
It is available in the Mondeo in conjunction with
In the event of failure of key electronic
the following engines:
components a hydraulic emergency running
• 2.5L Duratec programme provides restricted operation of the
• 2.0L Duratorq TDCi transmission.
The transmission ratios are achieved with three For one year initially no repairs are planned on
planetary gearsets on two shafts. The individual the transmission, apart from the replacement of
components are driven or held by means of four various oil seals, the main control body, individual
clutches, three brakes and two roller-type one- solenoid valves, the torque converter and the
way clutches. transmission range (TR) sensor.
A torque converter lock-up clutch (TCC) ensures Under normal operating conditions the
that fuel consumption is optimised. It is engaged transmission fluid is filled for service life of the
by the transmission control unit depending on the transmission and does not need to be changed.
vehicle speed and the engine load.
If the vehicle is stopped while a gear is engaged, At a glance
then the transmission control system ensures
that the transmission is shifted into neutral

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307-01B-5 Automatic Transmission/Transaxle — Vehicles With: 307-01B-5
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transmission layout

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307-01B-6 Automatic Transmission/Transaxle — Vehicles With: 307-01B-6

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• 5-speed automatic transmission for FWD • Gearshift timing is calculated by the
• Three simple planetary gearsets on two transmission control unit according to the
shafts individual driving style of the driver and the
current driving resistance.
• Transmission ratios achieved by means of
four multi-plate clutches, two multi-plate • Automatic gear selection by the transmission
brakes, one brake band and two one-way control unit or manual gear selection by the
clutches driver in Select-Shift-Mode
• The final drive is integrated into the • Automatic engagement of neutral when the
transmission housing. vehicle is stationary to stabilise idling and
reduce fuel consumption and emissions (only
• Electronically controlled, hydraulically
on vehicles with a diesel engine)
activatedTCC

Transmission ratios in the individual gears:

Gear Transmission ratio
1st gear 3.801
2nd gear 2.131
3rd gear 1.364
4th gear 0.935
5th gear 0.685
Reverse gear 2.970
Transmission control

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307-01B-7 Automatic Transmission/Transaxle — Vehicles With: 307-01B-7
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Transmission cross-section

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307-01B-8 Automatic Transmission/Transaxle — Vehicles With: 307-01B-8

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Torque converter with TCC
Number
1 - 3rd-5th gear clutch
2 - Reverse clutch
3 - 1st planetary gearset
4 - 2nd/4th/5th gear brake
5 - 2nd planetary gearset
6 - 1st-3rd gear clutch
7 - Reverse gear brake
8 - 1st gear one-way clutch
9 - Driven gear of 1st and 2nd
planetary gearset
10 - Stator shaft
11 - Oil pump
12 - Torque converter
13 - Transmission input shaft
14 - Intermediate shaft
15 - Driven gear of reduction
planetary gearset
16 - Differential assembly
17 - Drive gear for reduction
planetary gearset Item Part Description
18 - Reduction planetary gearset Number

19 - 5th gear clutch 1 - Torque converter housing

and impeller
20 - Reduction brake band
2 - Turbine
21 - Reduction one-way clutch
3 - Stator with roller-type one-
way clutch
4 - TCC
5 - Transmission input shaft
NOTE: Three different torque converters are
used, depending on the engine variant.
The torque converter hydraulically transmits the
output torque from the engine to the input shaft of
the transmission.
The stator increases the torque up to the clutch
point (approx. 90% speed difference between the
impeller and the turbine).
In order to increase the efficiency of the
automatic transmission, the torque converter is
also equipped with a hydraulically activated TCC

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307-01B-9 Automatic Transmission/Transaxle — Vehicles With: 307-01B-9
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

The torque converter lock-up clutch (is applied The oil pump is a G-rotor oil pump.
with controlled slip to ensure soft engagement.)
It sucks up transmission fluid from the sump,
When the TCC is engaged, the torque is builds up the oil pressure and then supplies it
transmitted directly from the crankshaft via the under high pressure to the main control body.
torque converter housing to the transmission
The oil pump is driven by the crankshaft via the
input shaft.
torque converter housing.
Under normal operating conditions, the TCC can
be activated in selector lever position "D" in 3rd,
4th and 5th gear, as well as in 2nd gear if the
temperature of the transmission fluid is too high.
When Select-Shift-Mode is activated the TCC
can be activated in all forward drive gears.

Oil pump

Item Part Description

Number
1 - Outer ring
2 - Inner ring
3 - Drive (input)
4 - Suction side
5 - High-pressure side

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307-01B-10 Automatic Transmission/Transaxle — Vehicles With: 307-01B-10
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

1. and 2nd planetary gearset

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307-01B-11 Automatic Transmission/Transaxle — Vehicles With: 307-01B-11
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
1 - Sun gear (1st set)
2 - Planetary gear carrier (1st
set)
3 - Ring gear (1st set) and
planetary gear carrier (2nd
set)
4 - Ring gear (2nd set)
5 - Sun gear (2nd set)
6 - Driven gear
7 - Transmission input shaft

The 1st and 2nd planetary gearsets are located

on the level of the transmission input shaft.
They are two simple planetary gearsets, whereby
the ring gear (1st set) and the planetary gear
carrier (2nd set) form a single component.
Through actuation of various clutches and
brakes, certain components of the planetary
gearsets are driven while others are held still.
The different combinations of driven/held
components result in different transmission
ratios.
Drive is output via the ring gear (1st set) and the
planetary gear carrier (2nd set) to the driven
gear.

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307-01B-12 Automatic Transmission/Transaxle — Vehicles With: 307-01B-12

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Reduction planetary gearset

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307-01B-13 Automatic Transmission/Transaxle — Vehicles With: 307-01B-13
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
1 - Sun gear
2 - Planetary gear carrier
3 - Ring gear
4 - Drive gear for reduction
planetary gearset
5 - Driven gear of reduction
planetary gearset
6 - Intermediate shaft
7 - Differential assembly
8 - Reduction gearing

The reduction planetary gearset is a simple

planetary gearset.
The ring gear of the reduction planetary gearset
is driven by the driven gear of the 1st and 2nd
planetary gearset via the drive gear of the
reduction planetary gearset.
Drive is always output via the planetary gear
carrier to the driven gear of the reduction
planetary gearset, and thereby to the differential.

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307-01B-14 Automatic Transmission/Transaxle — Vehicles With: 307-01B-14

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Clutches and brakes

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307-01B-15 Automatic Transmission/Transaxle — Vehicles With: 307-01B-15
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
1 - 3rd - 5th gear clutch
2 - Reverse clutch
3 - 2nd/4th/5th gear brake
4 - 1st - 3rd gear clutch
5 - Reverse gear brake
6 - 1st gear one-way clutch
7 - 5th gear clutch
8 - Reduction brake band
9 - Reduction one-way clutch

The transmission is equipped with four clutches

and five brakes.
The clutches are laid out as multi-plate clutches.
The brakes are made up of two multi-plate
brakes (2nd/4th/5th gear brake and reverse gear
brake), two one-way clutches (1st gear one-way
clutch and reduction one-way clutch) and one
brake band (reduction brake band).
The torque is transmitted via the clutches to
certain components in the planetary gearsets.
Other components in the planetary gearsets are
held with the brakes.
These combinations result in the different
transmission ratios for the individual gears.

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307-01B-16 Automatic Transmission/Transaxle — Vehicles With: 307-01B-16

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Differential assembly

The planetary gear carrier for the reduction

Item Part Description planetary gearset is rigidly linked via the
Number intermediate shaft to the driven gear of the
1 - Intermediate shaft reduction planetary gearset and drives the
differential.
2 - Driven gear of reduction
planetary gearset The differential assembly transmits the torque via
the drive halfshafts to the front wheels.
3 - Differential assembly
Any differences in rotational speed between the
4 - Planetary gear carrier for re- two drive halfshafts are compensated by the
duction planetary gearset differential.

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307-01B-17 Automatic Transmission/Transaxle — Vehicles With: 307-01B-17
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Control housing

The hydraulic lines and pressures are

Item Part Description electronically regulated by four pulse-width
Number modulated (PWM) solenoid valves and five shift
1 - Solenoid valves solenoid valves.

2 - Manual selector lever In addition, the manual selector lever in the main
control body provides a hydraulic emergency
The hydraulic pressure is distributed to the running programme, which allows the vehicle to
individual clutches and brakes in the main control drive in 4th gear with the selector lever in position
body. "D" and in reverse gear with the selector lever in
position "R".

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307-01B-18 Automatic Transmission/Transaxle — Vehicles With: 307-01B-18
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Identification Tags

Item Part Description

Number
1 - Transmission designation
2 - Manufacturer number

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307-01B-19 Automatic Transmission/Transaxle — Vehicles With: 307-01B-19
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transmission Ranges and Power Flow

Overview of operation
Component Connects P R N 1 2 3 4 5
1st - 3rd gear clutch Planetary gear carrier (1st set) and X X X
ring gear (2nd set)
3rd - 5th gear clutch Transmission input shaft and plane- X X X
tary gear carrier (1st set)
5th gear clutch Planetary gear carrier and sun gear X
(reduction gearset)
Reverse clutch Transmission input shaft and sun gear X
(1st set)
Reverse gear brake Transmission housing and planetary X X*
gear carrier (1st set)
2nd/4th/5th gear brake Transmission housing and sun gear X X X
(1st set)
Reduction brake band Transmission housing and sun gear X X X X* X* X X
(reduction gearset)
1st gear one-way clutch Transmission housing and planetary X
gear carrier (1st set)
Reduction one-way clutch Transmission housing and sun gear X X X X
(reduction gearset)
* Only in Select-Shift-Mode

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307-01B-20 Automatic Transmission/Transaxle — Vehicles With: 307-01B-20
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transmission in 1st gear

Item Part Description

Item Part Description Number
Number
5 - 1st gear one-way clutch
1 - Transmission input shaft
6 - Reverse gear brake
2 - Sun gear (2nd set)
7 - Planetary gear carrier (2nd
3 - Ring gear (2nd set) set) and ring gear (1st set).
4 - 1st - 3rd gear clutch

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307-01B-21 Automatic Transmission/Transaxle — Vehicles With: 307-01B-21
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description The planetary gears roll on the sun gear, which is
Number being held, and drive the planetary gear carrier
(14), which is rigidly linked to the driven gear of
8 - Driven gear of 1st and 2nd the reduction gearset (15).
planetary gearset
The driven gear of the reduction gearset drives
9 - Drive gear for reduction the differential (16).
gearset
10 - Ring gear (reduction
gearset)
11 - Sun gear (reduction gearset)
12 - Reduction one-way clutch
13 - Reduction brake band
14 - Planetary gear carrier (re-
duction gearset)
15 - Driven gear of reduction
gearset
16 - Differential assembly

1st and 2nd planetary gearset:

The drive is transmitted from the transmission
input shaft (1) to the sun gear (2nd set) (2).
The ring gear (2nd set) (3) is held by the 1st - 3rd
gear clutch (4) and the 1st gear one-way clutch
(5).
NOTE: In Select-Shift-Mode the ring gear (2nd
set) is also held by the reverse gear brake (6) via
the 1st - 3rd gear clutch (engine braking).
The planetary gears roll on the ring gear (2nd
set) which is being held, thereby driving the
planetary gear carrier (2nd set) and the ring gear
(1st set) (7).
The planetary gear carrier (2nd set) is rigidly
linked to the driven gear of the 1st and 2nd
planetary gearset (8).
The 1st planetary gearset has no influence on
the transmission.

Reduction planetary gearset:

The driven gear of the 1st and 2nd planetary
gearset drives the drive gear for the reduction
gearset (9), which is rigidly linked to the ring
gear (10).
The sun gear (11) is held by the one-way clutch
(12).
NOTE: In Select-Shift-Mode the sun gear is held
by the reduction brake band (13) (engine
braking).
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307-01B-22 Automatic Transmission/Transaxle — Vehicles With: 307-01B-22
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Power transmission route in first gear

Item Part Description

Item Part Description Number
Number
5 - Ring gear (2nd set)
1 - Impeller
6 - 1st - 3rd gear clutch
2 - Turbine
7 - 1st gear one-way clutch
3 - Transmission input shaft
8 - Reverse gear brake
4 - Sun gear (2nd set)

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307-01B-23 Automatic Transmission/Transaxle — Vehicles With: 307-01B-23
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description • Sun gear (13) via the reduction one-way
Number clutch (14) (no engine braking)
NOTE: In Select-Shift-Mode the sun gear is held
9 - Planetary gear carrier (2nd by the reduction brake band (15) (engine
set) and ring gear (1st set). braking).
10 - Driven gear of 1st and 2nd Drive (output)
planetary gearset • Planetary gear carrier (16)
11 - Drive gear for reduction - Driven gear of reduction gearset (17)
gearset - Differential (18)
12 - Ring gear (reduction
gearset)
13 - Sun gear (reduction gearset)
14 - Reduction one-way clutch
15 - Reduction brake band
16 - Planetary gear carrier (re-
duction gearset)
17 - Driven gear of reduction
gearset
18 - Differential assembly

1st and 2nd planetary gearset:

Drive (input)
• Impeller (1)
- Turbine (2)
- Transmission input shaft (3)
- Sun gear (2nd set) (4)
Held
• Ring gear (2nd set) (5) by the 1st gear one-
way clutch (7) (no engine braking) via the 1st
- 3rd gear clutch (6)
NOTE: In Select-Shift-Mode the ring gear (2nd
set) is held by the reverse gear brake (8) via the
1st - 3rd gear clutch (engine braking).
Drive (output)
• Planetary gear carrier (2nd set) and ring gear
(1st set) (9)
- Driven gear of 1st and 2nd planetary
gearset (10)

Reduction planetary gearset:

Drive (input)
• Drive gear for reduction gearset (11)
- Ring gear (12)
Held

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307-01B-24 Automatic Transmission/Transaxle — Vehicles With: 307-01B-24
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transmission in 2nd gear

Item Part Description

Item Part Description Number
Number
5 - 1st gear one-way clutch
1 - Transmission input shaft
7 - Planetary gear carrier (2nd
2 - Sun gear (2nd set) set) and ring gear (1st set).
3 - Ring gear (2nd set) 8 - Driven gear of 1st and 2nd
4 - 1st - 3rd gear clutch planetary gearset

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307-01B-25 Automatic Transmission/Transaxle — Vehicles With: 307-01B-25
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
17 - 2nd/4th/5th gear brake
18 - Sun gear (1st set)
19 - Planetary gear carrier (1st
set)

1st and 2nd planetary gearset:

The drive is transmitted from the transmission
input shaft (1) to the sun gear (2nd set) (2).
The ring gear (2nd set) (3) is initially held by the
1st - 3rd gear clutch (4) and the 1st gear one-way
clutch (5).
As a result, the planetary gears roll on the ring
gear (2nd set) which is being held, thereby
driving the planetary gear carrier (2nd set) and
the ring gear (1st set) (7).
The planetary gears (1st set) roll on the sun gear
(1st set) (18) which is being held by the
2nd/4th/5th gear brake (17).
As a result, they drive the planetary gear carrier
(1st set) (19), and therefore also the ring gear
(2nd set) via the 1st - 3rd gear clutch.
The resulting relative movement is transmitted
via the planetary gear carrier (2nd set) to the
driven gear of the 1st and 2nd planetary gearset
(8).

Reduction planetary gearset:

See 1st gear.

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307-01B-26 Automatic Transmission/Transaxle — Vehicles With: 307-01B-26

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Power transmission route in second gear

Item Part Description

Item Part Description Number
Number
9 - Planetary gear carrier (2nd
1 - Impeller set) and ring gear (1st set).
2 - Turbine 10 - Driven gear of 1st and 2nd
3 - Transmission input shaft planetary gearset

4 - Sun gear (2nd set) 19 - Sun gear (1st set)

20 - 2nd/4th/5th gear brake

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307-01B-27 Automatic Transmission/Transaxle — Vehicles With: 307-01B-27
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

1st and 2nd planetary gearset: • Planetary gear carrier (2nd set) and ring gear
(1st set) (9)
Drive (input)
- Driven gear of 1st and 2nd planetary
• Impeller (1)
gearset (10)
- Turbine (2)
- Transmission input shaft (3)
Reduction planetary gearset:
- Sun gear (2nd set) (4)
Held See 1st gear.
• Sun gear (1st set) (19) by the 2nd/4th/5th
gear brake (20)
Drive (output) Transmission in 3rd gear

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307-01B-28 Automatic Transmission/Transaxle — Vehicles With: 307-01B-28

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description gearset (9), which is rigidly linked to the ring
Number gear (10).

1 - Transmission input shaft The sun gear (11) is held by the reduction brake
band (13) (engine braking).
2 - Sun gear (2nd set)
The planetary gears roll on the sun gear, which
3 - Ring gear (2nd set) is being held, and drive the planetary gear carrier
(14), which is rigidly linked to the driven gear of
4 - 1st - 3rd gear clutch
the reduction gearset (15).
7 - Planetary gear carrier (2nd
The driven gear of the reduction gearset drives
set) and ring gear (1st set).
the differential (16).
8 - Driven gear of 1st and 2nd
planetary gearset
9 - Drive gear for reduction
gearset
10 - Ring gear (reduction
gearset)
11 - Sun gear (reduction gearset)
13 - Reduction brake band
14 - Planetary gear carrier (re-
duction gearset)
15 - Driven gear of reduction
gearset
16 - Differential assembly
19 - Planetary gear carrier (1st
set)
20 - 3rd - 5th gear clutch

1st and 2nd planetary gearset:

Drive is transmitted from the transmission input
shaft (1) to the sun gear (2nd set) (2) and via the
3rd - 5th gear clutch (20) to the planetary gear
carrier (1st set) (19). The planetary gear carrier
(1st set) drives the ring gear (2nd set) (3) via the
1st - 3rd gear clutch (4).
As two components are being driven
simultaneously in the 2nd planetary gearset,
there is no resulting relative movement. The
planetary gearsets rotate as complete units.
The planetary gear carrier (2nd set) and the ring
gear (1st set) (7) are rigidly linked to the driven
gear of the 1st and 2nd planetary gearset (8).

Reduction planetary gearset:

The driven gear of the 1st and 2nd planetary
gearset drives the drive gear for the reduction

G188995 en 08/2002 2003.0 Mondeo

307-01B-29 Automatic Transmission/Transaxle — Vehicles With: 307-01B-29
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Power transmission route in third gear

Item Part Description

Item Part Description Number
Number
5 - Ring gear (2nd set)
1 - Impeller
6 - 1st - 3rd gear clutch
2 - Turbine
9 - Planetary gear carrier (2nd
3 - Transmission input shaft set) and ring gear (1st set).
4 - Sun gear (2nd set)

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307-01B-30 Automatic Transmission/Transaxle — Vehicles With: 307-01B-30

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description - Driven gear of 1st and 2nd planetary
Number gearset (10)

10 - Driven gear of 1st and 2nd

planetary gearset Reduction planetary gearset:

11 - Drive gear for reduction Drive (input)

gearset • Drive gear for reduction gearset (11)
12 - Ring gear (reduction - Ring gear (12)
gearset) Held
• Sun gear (13) via the reduction one-way
13 - Sun gear (reduction gearset) clutch (15) (no engine braking)
15 - Reduction brake band Drive (output)
• Planetary gear carrier (16)
16 - Planetary gear carrier (re-
duction gearset) - Driven gear of reduction gearset (17)
- Differential (18)
17 - Driven gear of reduction
gearset
18 - Differential assembly
21 - 3rd - 5th gear clutch
22 - Planetary gear carrier (1st
set)
23 - Torque con-
verter lock-up clutch (TCC)

1st and 2nd planetary gearset:

Drive (input)
• Impeller (1)
- Turbine (2)
- Transmission input shaft (3)
- Sun gear (2nd set) (4)
• Impeller (1)
- Turbine (2)
- Transmission input shaft (3)
- 3rd - 5th gear clutch (21)
- Planetary gear carrier (1st set) (22)
- 1st - 3rd gear clutch (6)
- Ring gear (2nd set) (5)
NOTE: When the TCC(23) is engaged the drive
is transmitted directly from the torque converter
housing to the transmission input shaft.
Held
• No components
Drive (output)
• Planetary gear carrier (2nd set) and ring gear
(1st set) (9)

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307-01B-31 Automatic Transmission/Transaxle — Vehicles With: 307-01B-31
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transmission in 4th gear

Item Part Description

Item Part Description Number
Number
17 - 2nd/4th/5th gear brake
1 - Transmission input shaft
18 - Sun gear (1st set)
7 - Planetary gear carrier (2nd
set) and ring gear (1st set). 19 - Planetary gear carrier (1st
set)
8 - Driven gear of 1st and 2nd
planetary gearset 20 - 3rd - 5th gear clutch

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307-01B-32 Automatic Transmission/Transaxle — Vehicles With: 307-01B-32

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

1st and 2nd planetary gearset: This is rigidly linked to the driven gear of the 1st
and 2nd planetary gearset (8).
Drive is transmitted from the transmission input
shaft (1) via the 3rd - 5th gear clutch (20) to the The 2nd planetary gearset has no influence on
planetary gear carrier (1st set) (19). the transmission.
The planetary gears (1st set) roll on the sun gear
(1st set) (18) which is being held by the Reduction planetary gearset:
2nd/4th/5th gear brake (17).
See 3rd gear.
As a result, the planetary gear carrier (2nd set)
and the ring gear (1st set) (7) are driven.
Power transmission route in fourth gear

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307-01B-33 Automatic Transmission/Transaxle — Vehicles With: 307-01B-33
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
1 - Impeller
2 - Turbine
3 - Transmission input shaft
9 - Planetary gear carrier (2nd
set) and ring gear (1st set).
10 - Driven gear of 1st and 2nd
planetary gearset
19 - Sun gear (1st set)
20 - 2nd/4th/5th gear clutch
21 - 3rd - 5th gear clutch
22 - Planetary gear carrier (1st
set)
23 - TCC

1st and 2nd planetary gearset:

Drive (input)
• Impeller (1)
- Turbine (2)
- Transmission input shaft (3)
- 3rd - 5th gear clutch (21)
- Planetary gear carrier (1st set) (22)
NOTE: When the TCC(23) is engaged the drive
is transmitted directly from the torque converter
housing to the transmission input shaft.
Held
• Sun gear (1st set) (19) by the 2nd/4th/5th
gear brake (20)
Drive (output)
• Planetary gear carrier (2nd set) and ring gear
(1st set) (9)
- Driven gear of 1st and 2nd planetary
gearset (10)

Reduction planetary gearset:

See 3rd gear.

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307-01B-34 Automatic Transmission/Transaxle — Vehicles With: 307-01B-34

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Transmission in 5th gear

Item Part Description

Item Part Description Number
Number
11 - Sun gear (reduction gearset)
8 - Driven gear of 1st and 2nd
planetary gearset 14 - Planetary gear carrier (re-
duction gearset)
9 - Drive gear for reduction
gearset 15 - Driven gear of reduction
gearset
10 - Ring gear (reduction
gearset) 16 - Differential assembly

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307-01B-35 Automatic Transmission/Transaxle — Vehicles With: 307-01B-35
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
21 - 5th gear clutch

1st and 2nd planetary gearset:

See 4th gear.

Reduction planetary gearset:

The driven gear of the 1st and 2nd planetary
gearset (8) drives the drive gear for the reduction
gearset (9), which is rigidly linked to the ring
gear (10).
The 5th gear clutch (21) connects the planetary
gear carrier (14) with the sun gear (11). As a
result there are no relative movements between
these components. The planetary gearset
rotates as a complete unit.
The planetary gear carrier is rigidly linked to the
driven gear of the reduction gearset (15).
The driven gear of the reduction gearset drives
the differential (16).

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307-01B-36 Automatic Transmission/Transaxle — Vehicles With: 307-01B-36

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Power transmission route in fifth gear

Item Part Description

Item Part Description Number
Number
16 - Planetary gear carrier (re-
11 - Drive gear for reduction duction gearset)
gearset
17 - Driven gear of reduction
12 - Ring gear (reduction gearset
gearset)
18 - Differential assembly
13 - Sun gear (reduction gearset)
24 - 5th gear clutch

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307-01B-37 Automatic Transmission/Transaxle — Vehicles With: 307-01B-37
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

1st and 2nd planetary gearset: • No components
See 4th gear. NOTE: The planetary gear carrier (16) and the
sun gear (13) are coupled via the 5th gear clutch
(24). The planetary gearset rotates as a
Reduction planetary gearset: complete unit.
Drive (input) Drive (output)
• Drive gear for reduction gearset (11) • Planetary gear carrier (16)
- Ring gear (12) - Driven gear of reduction gearset (17)
Held - Differential (18)

Transmission in reverse gear

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307-01B-38 Automatic Transmission/Transaxle — Vehicles With: 307-01B-38

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description gearset (9), which is rigidly linked to the ring
Number gear (10).

1 - Transmission input shaft The sun gear (11) is held by the reduction brake
band (13).
6 - Reverse gear brake
The planetary gears roll on the sun gear, which
7 - Planetary gear carrier (2nd is being held, and drive the planetary gear carrier
set) and ring gear (1st set). (14), which is rigidly linked to the driven gear of
the reduction gearset (15).
8 - Driven gear of 1st and 2nd
planetary gearset The driven gear of the reduction gearset drives
the differential (16).
9 - Drive gear for reduction
gearset
10 - Ring gear (reduction
gearset)
11 - Sun gear (reduction gearset)
13 - Reduction brake band
14 - Planetary gear carrier (re-
duction gearset)
15 - Driven gear of reduction
gearset
16 - Differential assembly
18 - Sun gear (1st set)
19 - Planetary gear carrier (1st
set)
22 - Reverse clutch

1st and 2nd planetary gearset:

Drive is transmitted from the transmission input
shaft (1) via the reverse clutch (22) to the sun
gear (1st set) (18).
The planetary gear carrier (1st set) (19) is held
by the reverse gear brake (6).
The planetary gears (1st set) drive the planetary
gear carrier (2nd set) and the ring gear (1st set)
(7).
The planetary gear carrier (2nd set) is rigidly
linked to the driven gear of the 1st and 2nd
planetary gearset (8).
The 2nd planetary gearset has no influence on
the transmission.

Reduction planetary gearset:

The driven gear of the 1st and 2nd planetary
gearset drives the drive gear for the reduction

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307-01B-39 Automatic Transmission/Transaxle — Vehicles With: 307-01B-39
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Power transmission route in reverse gear

Item Part Description

Item Part Description Number
Number
9 - Planetary gear carrier (2nd
1 - Impeller set) and ring gear (1st set).
2 - Turbine 10 - Driven gear of 1st and 2nd
3 - Transmission input shaft planetary gearset

8 - Reverse gear brake 11 - Drive gear for reduction

gearset

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307-01B-40 Automatic Transmission/Transaxle — Vehicles With: 307-01B-40

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description - Turbine (2)
Number - Transmission input shaft (3)
12 - Ring gear (reduction - Reverse clutch (25)
gearset) - Sun gear (1st set) (19)
Held
13 - Sun gear (reduction gearset)
• Planetary gear carrier (1st set) (22) by the
15 - Reduction brake band reverse gear brake (8)
Drive (output)
16 - Planetary gear carrier (re-
duction gearset) • Planetary gear carrier (2nd set) and ring gear
(1st set) (9)
17 - Driven gear of reduction
- Driven gear of 1st and 2nd planetary
gearset
gearset (10)
18 - Differential assembly
19 - Sun gear (1st set) Reduction planetary gearset:
22 - Planetary gear carrier (1st Drive (input)
set) • Drive gear for reduction gearset (11)
25 - Reverse clutch - Ring gear (12)
Held
• Sun gear (13) via the reduction brake band
1st and 2nd planetary gearset: (15)
Drive (input) Drive (output)
• Impeller (1) • Planetary gear carrier (16)
- Driven gear of reduction gearset (17)
- Differential (18)

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307-01B-41 Automatic Transmission/Transaxle — Vehicles With: 307-01B-41
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transaxle Electronic Control System

Overview

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307-01B-42 Automatic Transmission/Transaxle — Vehicles With: 307-01B-42
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transmission control unit
Item Part Description
Number
1 - Transmission control unit
2 - Data Link Con-
nector (DLC)
3 - Turbine Shaft
Speed (TSS) sensor
4 - Intermediate shaft speed
sensor
5 - Output Shaft
Speed (OSS) sensor
6 - Transmission
Fluid Temperature (TFT) Item Part Description
sensor Number
7 - Transmission 1 - Transmission control unit
Range (TR) sensor
2 - A-pillar
8 - Backup lamp relay
Installation position.
9 - Select-Shift switch • The transmission control unit is located in the
10 - Brake pressure switch (only passenger compartment at the left-hand A-
on vehicles with a diesel en- pillar.
gine and no ESP) Function

11 - Stoplamp switch
12 - Selector lever lock solenoid
13 - Solenoid for the ignition key
removal inhibitor
14 - Generic Elec-
tronic Module (GEM)
15 - Park display in the instru-
ment cluster
16 - Instrument Cluster
17 - Solenoid valves in the main
control body
18 - ESP control unit
19 - Powertrain
Control Module (PCM)

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307-01B-43 Automatic Transmission/Transaxle — Vehicles With: 307-01B-43
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• The transmission control unit evaluates Mode Priority
incoming signals and controls the actuators Normal 9
accordingly. Auto/sport 8
Hill climb 7
Cold start 6
Overheating protection 5
Stop & go 4
Fast off 3
Hill descent 2
Select-Shift 1
Emergency running 0

Normal mode
Normal mode is the shift strategy employed when
the selector lever is in position "D".
In normal mode the transmission control unit
selects the shift strategy according to the
following criteria transmitted by the PCM:
• Throttle valve slightly open
• Throttle valve approximately half open
• Throttle valve wide open
When the throttle valve is slightly open, the shift
pattern is calculated to minimise fuel
consumption and pollutant emissions, whilst
simultaneously providing a comfortable ride.
With the throttle valve around half open, the shift
timing is mostly adapted to ride comfort.
When the throttle valve is in the wide open
Item Part Description position, the timing of the gearshifts is calculated
Number for maximum power.
1 - WDS
2 - DLC Auto/sport mode

Diagnosis The auto/sport mode is designed to offer drivers

• The transmission control can be diagnosed with a more sporty driving style a shift strategy to
via the data link connector (DLC) in the suit their needs. The transmission control unit
passenger compartment. shifts down earlier (at higher engine speeds),
particularly under part load conditions.
The PCM detects the speed with which the
Shift strategy accelerator pedal is depressed and passes this
information on to the transmission control unit
The shift strategy employed by the transmission
Once the speed with which the accelerator pedal
control unit depends on various operating
is depressed exceeds a certain threshold, the
conditions. The transmission control unit makes
transmission control unit switches into auto/sport
an overall distinction between ten different
mode and alters the shift timing accordingly.
strategies, which are applied in a defined order of
priority.
The following table shows the different strategies Hill climb mode
(modes) together with their assigned priority The hill climb mode is utilised to avoid
(lowest number = highest priority). unnecessary switching back and forth between
gears.

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307-01B-44 Automatic Transmission/Transaxle — Vehicles With: 307-01B-44

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

The transmission control unit calculates the into 1st gear. The vehicle will then also pull away
gradient according to the change in the from standing in 2nd gear.
accelerator pedal position detected by the PCM
If the transmission control unit detects higher
in relation to the acceleration of the vehicle.
vehicle speeds or wider opening of the throttle
Depending on the calculated gradient, upshifts valve, then it automatically exits the stop & go
from 4th to 5th gear, 3rd to 4th gear or 2nd to 3rd mode.
gear are prevented.
Fast off mode
Cold start mode
The fast off mode prevents instantaneous
Cold start mode is employed when it is important upshifts when the accelerator pedal is suddenly
to get the transmission fluid up to operating released.
temperature as quickly as possible.
In order to give the driver a more direct driving
At transmission fluid temperatures below approx. experience and to better exploit engine braking
30 °C, the Torque Converter Clutch (TCC) is not (e.g. during fast cornering), the system
engaged. suppresses an immediate upshift to the next
higher gear at vehicle speeds above approx. 50
At transmission fluid temperatures below approx.
km/h if the accelerator pedal is suddenly
5 °C, gearshifts into 5th gear are disabled.
released.
The transmission control unit exits the cold start
mode when the transmission fluid temperature
exceeds 10 °C, or after a maximum of 10 Hill descent mode
minutes. The hill descent mode is used to take better
advantage of engine braking during hill descents.
Overheating protection mode At vehicle speeds above approx. 25 km/h the
transmission control unit prevents upshifts if the
The overheating protection mode serves to
throttle valve is closed. Depending on the current
protect the transmission against overheating and
driving conditions, the system suppresses
the serious damage it can cause.
gearshifts into 3rd, 4th or 5th gear.
If the transmission fluid temperature reaches a
If under these conditions the brake is depressed
temperature of around 120 °C or if the Engine
for approx. 0.2 seconds, then the transmission
Coolant Temperature (ECT) reaches approx. 115
control unit also shifts down a gear if the
°C, the transmission control employs a shift
conditions permit.
pattern designed to prevent a further increase in
the transmission fluid temperature. In addition, NOTE: Repeated operation of the brake pedal
the TCC is also engaged in 2nd gear in order to can lead to further downshifts.
reduce the temperature of the transmission fluid.
If the throttle valve is opened further or the
When the transmission fluid temperature drops vehicle speed drops below around 25 km/h then
back below approx. 117 °C or the ECT drops the transmission control exits the hill descent
back below approx. 111 °C, the transmission mode.
control exits the overheating protection mode.
Select-Shift-Mode
Stop & go mode
The Select-Shift-Mode is selected directly by the
NOTE: Stop & go mode only applies to vehicles driver and is designed to give the driver a more
with a 2.5L Duratec engine. direct driving experience.
Stop & go mode prevents over-frequent The transmission control ensures that no damage
gearshifts when the vehicle is in stop & go traffic. can be caused as a result of inappropriate
operation of the system.
The transmission control unit counts the number
of accelerator pedal actuations transmitted by the
PCM within a certain time and compares them to
the vehicle speed. If the transmission control unit
detects stop & go mode it suppresses gearshifts

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307-01B-45 Automatic Transmission/Transaxle — Vehicles With: 307-01B-45
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• If the upper engine speed limit is reached
then the transmission control unit
automatically shifts up to the next gear.
• If the engine speed drops below a certain
value then the transmission control unit
automatically shifts down a gear.
• If the action of shifting down a gear would
cause the engine to rev above its maximum
speed limit then the transmission control unit
does not allow the downshift to take place.
Select-Shift-Mode allows the driver to pull away
from standing in 2nd gear (winter operation) and
enables kick-down up to around 80 km/h.

Emergency running mode

If due to the failure of certain signals the

transmission control unit can no longer ensure
that the correct gearshifts are performed, then it
automatically switches into emergency running
mode. In this case the transmission control unit
no longer actuates the solenoids in the main
control body.
The driver can drive on, but the following
restrictions apply:
• Maximum line pressure (harsh engagement).
• 4th gear in selector lever position "D" without
TCC ,
• Reverse gear in selector lever position "R".
The emergency running mode is implemented via
the manual selector lever in the main control
body. All gearshifts are controlled purely
hydraulically.
The emergency running mode is indicated with
two horizontal lines on the instrument cluster (see
illustration).

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307-01B-46 Automatic Transmission/Transaxle — Vehicles With: 307-01B-46

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Electronically synchronised gearshift control

Gearshift Item Part Description

Number
Item Part Description
Number B - Asynchronous gearshift
(pressure released too early
1 - Pressure of the component on the component which is
which is to be disengaged to be disengaged)
2 - Pressure of the component C - Asynchronous gearshift
which is to be engaged (pressure released too late
on the component which is
3 - Turbine shaft speed
to be disengaged)
4 - Synchronisation range for
the gearshift
Control of the gearshifts with an electronically
A - Synchronous gearshift synchronised gearshift control
During a gearshift, certain gearshift elements are
released while others are simultaneously
pressurised. Ideally this process should be
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307-01B-47 Automatic Transmission/Transaxle — Vehicles With: 307-01B-47
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

synchronised, i.e. the two parts should take place The electronically synchronised gearshift control
simultaneously in order to avoid judder during the monitors the gearshift time on the one hand, and
gearshift. on the other hand checks that the gearshift is
synchronised.
If the pressure is released too early (B) at the
element which is to be disengaged, this would If the electronically synchronised gearshift control
cause an unwanted increase in the turbine shaft detects a deviation from the values programmed
speed and the engine speed, as the element into the transmission control unit then the
which is to be engaged cannot yet transmit the hydraulic pressure is adapted for the gearshift.
input torque.
This enables the transmission control to adapt
If the pressure is released too late (C) at the the gearshift patterns over the service life of the
element which is to be disengaged, this would transmission to the changing requirements
cause a drop in the turbine shaft speed, as both resulting from component wear, so that good
gearshift elements would transmit the input gearshift quality is maintained throughout.
torque. An internal lock-up would cause the
torque to be transmitted to the transmission
housing in this case. Signal transmission on the CAN databus
In both cases a judder would be felt during the
gearshift. NOTE: On vehicles without electronic stability
A timeframe is also set for the gearshift which program (ESP), the Anti-lock Brake System
should not be exceeded. Normal wear on the (ABS) control unit is not connected to the CAN
gearshift elements would, after a long service life, databus.
cause an increase in the time taken for the
gearshift.

Item Part Description

Item Part Description Number
Number
2 - PCM
1 - Transmission control unit

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307-01B-48 Automatic Transmission/Transaxle — Vehicles With: 307-01B-48

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description signal is used by the transmission control unit for
Number automatic engagement of neutral when the
vehicle is stationary.
3 - ESP control unit
4 - Instrument Cluster Torque reduction signal
The transmission control unit signals its intention
Installation position. to perform a gearshift via the CAN databus to the
PCM.
The PCM is located on the right-hand side of the
interior near the bulkhead. The electrical The PCM then reduces the engine torque,
connector is accessible from the engine ensuring that the gearshift is as smooth and
compartment. judder-free as possible.
The ESP control unit forms a single component
together with the hydraulic unit. The hydraulic Vehicle speed signal
unit is located in the engine compartment
The vehicle speed signal is sent from the
underneath the brake booster.
transmission control unit via the CAN databus to
the PCM.
Engine speed The PCM processes the signal and forwards it,
The PCM receives an engine speed signal from again via the CAN databus, as the vehicle speed
the Crankshaft Position (CKP) sensor. to the instrument cluster.
This signal is transmitted via the CAN databus to On vehicles with ESP, the PCM utilises the signal
the transmission control unit. from the ABS wheel sensors, which is received
via the CAN databus.
The transmission control unit uses this signal for
the following functions:
• controlling the TCC Selector lever position
• automatically engaging neutral when the The transmission control unit broadcasts the
vehicle is stationary (vehicles with a diesel selector lever position and the engaged gear via
engine only) the CAN databus.
The instrument cluster indicates the selector
Load signal lever position or the engaged gear (Select-Shift-
Mode) to the driver.
The PCM determines a load signal, which is
transmitted via the CAN databus to the
transmission control unit.
The transmission control unit uses this signal for
the following functions:
• determination of the shift strategy
• determination of the main line pressure
• determination of the gearshift timing

Brake pressure signal

NOTE: Vehicles with a diesel engine and no ESP
are equipped with a separate brake pressure
switch, which sends the brake pressure signal
directly (not via the CAN databus) to the
transmission control unit.
On vehicles with a diesel engine and ESP, a
brake pressure signal is sent from the ESP
control unit to the transmission control unit. This

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307-01B-49 Automatic Transmission/Transaxle — Vehicles With: 307-01B-49
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

TSS sensor • harsher gearshifts
• no automatic engagement of neutral when the
vehicle is stationary (vehicles with a diesel
engine only)
• hill climb mode and hill descent mode
unavailable

Intermediate shaft speed sensor

Installation position.
• The TSS sensor is located in the transmission
above the reverse clutch.
Use of the signal
• The TSS sensor is an inductive pickup which
detects the rotational speed of the
transmission input shaft via the outer side of
the reverse clutch.
• The signal is used for the following functions: Installation position.
- controlling the main line pressure, • The intermediate shaft speed sensor is
- controlling the TCC. located in the transmission above the driven
Consequences of signal failure gear of the 1st and 2nd planetary gearset.
Use of the signal
• The intermediate shaft speed sensor is an
inductive pickup which detects the rotational
speed via the driven gear of the 1st and 2nd
planetary gearset.
• The signal is used to calculate the timing for
engagement and disengagement of the
clutches and brakes.
Consequences of signal failure

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307-01B-50 Automatic Transmission/Transaxle — Vehicles With: 307-01B-50

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• harsher gearshifts • harsher gearshifts
• no automatic engagement of neutral when the
vehicle is stationary (vehicles with a diesel
OSS sensor engine only)
• hill climb mode and hill descent mode
unavailable

TFT sensor

Installation position.
• The OSS sensor is located in the
transmission above the parking gear.
Use of the signal
• The OSS sensor is an inductive pickup which
detects the rotational output speed of the
reduction planetary gearset via the parking Item Part Description
gear. Number
• The parking gear sits on the planetary gear
1 - TFT sensor
carrier of the reduction gearset.
Installation position.
• The signal is used for the following functions:
• The TFT sensor is located in the transmission
- determination of the gearshift timing
underneath the oil filter.
- determination of the main line pressure Use of the signal
- controlling the TCC • The TFT sensor is an NTC resistor which
- as an input signal for the vehicle speed. determines the transmission fluid
Consequences of signal failure temperature.
• The transmission fluid temperature is used by
the transmission control unit for the following
functions:

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307-01B-51 Automatic Transmission/Transaxle — Vehicles With: 307-01B-51
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

- determination of the gearshift timing • harsher gearshifts
- determination of the main line pressure • auto/sport, hill climb and hill descent modes
- controlling the TCC unavailable
- overheating protection mode • no automatic engagement of neutral when the
vehicle is stationary (vehicles with a diesel
- cold start mode
engine only)
Consequences of signal failure
• The signal from the ECT sensor is used as a
substitute value. Select-Shift switch
• Cold start mode is unavailable.

TR sensor

Item Part Description

Number

Installation position. 1 - Carrier plate

• The TR sensor is located on the selector 2 - Hall sensors
shaft near the top of the transmission Installation position.
housing.
Use of the signal • The Select-Shift switch is located on the
selector lever.
• In the TR sensor there are four Hall senders Use of the signal
with an integrated circuit which enable
contact-free detection of the selector lever • The Select-Shift consists of three Hall
position. sensors and an integrated circuit.
• Their output signals are digital. • The signals from the Hall sensors are
converted in the integrated circuit to two
• The signal from the TR sensor is used for the digital output signals which are then
following functions: transmitted to the transmission control unit.
- detecting the selector lever position, The transmission control unit uses these
- actuating the backup lamp relay signals to detect driver demands.
- determining the main line pressure • If the driver moves the selector lever to the
Consequences of signal failure right-hand shift gate, then the transmission
control goes into Select-Shift mode.
• When the selector lever is pulled backwards
(+), the transmission control shifts up a gear if
the vehicle speed permits.
• When the selector lever is pushed forwards (-
), the transmission control shifts down a gear
if the vehicle speed permits.
• If the transmission control unit does not allow
the gearshift to take place because the
engine speed is too high or too low, then it

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307-01B-52 Automatic Transmission/Transaxle — Vehicles With: 307-01B-52

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

does not store the desired gear change and • Select-Shift-Mode is unavailable.
perform it at a later stage.
Consequences of signal failure

Internal and external signals

Selector lever Hall sensor 1 Hall sensor 2 Hall sensor 3 Output of line Output of line
position (+) (M) (-) 1 2
D Off Off Off 1 1
M Off On Off 0 0
+ Off On On 1 0
- On On Off 0 1
- release of the selector lever lock solenoid
- for disengagement of the TCC
Stoplamp switch
- for hill descent mode
Consequences of signal failure
• The selector lever cannot be moved out of the
"P" position.
• Hill descent mode is unavailable.

Brake pressure switch

Item Part Description

Number
1 - Brake pressure switch
2 - Plug connection
Item Part Description NOTE: The brake pressure switch is only fitted
Number on vehicles with a diesel engine and no ESP.
Installation position.
1 - Stoplamp switch
• The brake pressure switch is located in the
Installation position. engine compartment underneath the fuel
• The stoplamp switch is located on the brake filter. It is integrated in the brake circuit
pedal. leading to the front right-hand brake caliper.
Use of the signal Use of the signal
• The signal from the stoplamp switch is used
for the following functions:

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307-01B-53 Automatic Transmission/Transaxle — Vehicles With: 307-01B-53
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• The brake pressure switch supplies a signal • no automatic engagement of neutral when the
to the transmission control unit whenever vehicle is stationary (vehicles with a diesel
brake pressure is built up. engine only)
• The signal is only used for automatic
engagement of neutral when the vehicle is
stationary (only on vehicles with a diesel
engine).
Consequences of signal failure

Overview of solenoids in the main control body

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307-01B-54 Automatic Transmission/Transaxle — Vehicles With: 307-01B-54

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
1 - PWM solenoid - 3rd-5th gear 1 - Main regulating valve
clutch Function
2 - Main regulating valve • The main regulating valve is a pulse-width
modulated (PWM) solenoid.
3 - PWM solenoid - TCC
• It controls the main line pressure according to
4 - Shift solenoid SSA the driving conditions. This ensures smooth,
5 - Shift solenoid - reduction judder-free gearshifts.
brake band Consequences of component failure
• maximum line pressure
6 - Shift solenoid SSB
• harsh gearshifts
7 - Shift solenoid SSC
8 - PWM solenoid - 2nd/4th/5th
gear brake PWM solenoid - 2nd/4th/5th gear brake

9 - Shift solenoid - engagement

of neutral

Main regulating valve

Item Part Description

Number
1 - PWM solenoid - 2nd/4th/5th
gear brake
Function
• The PWM solenoid - 2nd/4th/5th controls the
fluid pressure during engagement and

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307-01B-55 Automatic Transmission/Transaxle — Vehicles With: 307-01B-55
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

disengagement of the 2nd/4th/5th gear brake. • maximum line pressure
gear brake • harsh gearshifts
Consequences of component failure
• maximum line pressure
• harsh gearshifts PWM solenoid - TCC

PWM solenoid - 3rd-5th gear clutch

Item Part Description

Number
1 - PWM solenoid - TCC
Item Part Description
Number Function
• The TCC PWM solenoid controls the
1 - PWM solenoid - 3rd-5th gear pressure during engagement and
clutch disengagement of the TCC.
Function • When there is no electrical supply, the TCC is
• The PWM solenoid - 3rd-5th gear clutch disengaged.
controls the fluid pressure during engagement Consequences of component failure
and disengagement of the 3rd-5th gear
clutch.
Consequences of component failure

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307-01B-56 Automatic Transmission/Transaxle — Vehicles With: 307-01B-56

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• TCC cannot be engaged. Item Part Description
Number

Shift solenoids SSA, SSB and SSC 1 - SSA

2 - SSB
3 - SSC
Function
• Shift solenoids SSA, SSB and SSC connect
the different hydraulic paths to the clutches
and brakes in the main control body.
Consequences of component failure
• If the transmission control unit detects a
malfunction in the SSA, SSB or SSC, it
automatically changes into emergency
running mode.

Shift solenoid Engaged gear

1 1* 2 3 4 5
SSA On Off On Off Off On
SSB On On On On Off Off
SSC On On Off Off On On
* 1. gear with engine braking (Select-Shift-Mode)

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307-01B-57 Automatic Transmission/Transaxle — Vehicles With: 307-01B-57
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

Shift solenoid - reduction brake band • harsher downshifts

Shift solenoid - engagement of neutral

Item Part Description

Number
Item Part Description
1 - Shift solenoid - reduction Number
brake band
Function 1 - Shift solenoid - engagement
of neutral
• The reduction brake band shift solenoid
controls the engagement and disengagement Function
of the reduction brake band. • The shift solenoid for engagement of neutral
Consequences of component failure performs the following tasks:
- realisation of the automatic function for
engaging neutral when the vehicle is
stationary (vehicles with a diesel engine
only)
- prevention of severe transmission damage
if reverse gear is engaged at a forward
vehicle speed above around 8 km/h.
Consequences of component failure
• No automatic engagement of neutral when
the vehicle is stationary (vehicles with a
diesel engine only)
• It would not be possible to prevent severe
transmission damage if reverse gear was

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307-01B-58 Automatic Transmission/Transaxle — Vehicles With: 307-01B-58

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

engaged while the vehicle was driving • When the ignition is switched on, the selector
forwards. lever lock solenoid is actuated by depressing
the brake pedal (signal from the stoplamp
switch). This results in the locking pin being
Selector lever lock solenoid pulled back, and the selector lever can be
moved out of "P".
• The ground connection to the solenoid for the
ignition key removal inhibitor is also made via
the selector lever lock solenoid in all selector
lever positions except "P".
• This ground connection is also used to inform
the instrument cluster and the GEM whether
or not the selector lever is in position "P".
Consequences of component failure
• If the selector lever lock solenoid is defective,
or if the signal from the stoplamp switch is
missing or the ground connection is
interrupted, then the selector lever cannot be
moved out of the position "P".
• The selector lever lock can be manually
released by removing the cover and pressing
a suitable object into the opening until the
selector lever can be moved out of the
position "P".
• The selector lever then re-locks if it is moved
back to "P".

Solenoid for the ignition key removal inhibitor

Item Part Description

Number
1 - Selector lever lock solenoid
2 - Locking pin
3 - Opening for manual release
Installation position.
• The selector lever lock solenoid is located in
the selector lever console.
Function
Item Part Description
Number
1 - Solenoid for the ignition key
removal inhibitor
Installation position.
• The solenoid for the ignition key removal
inhibitor is integrated in the ignition lock.
Function

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307-01B-59 Automatic Transmission/Transaxle — Vehicles With: 307-01B-59
5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

• With the selector lever in position "P", the Item Part Description
ground connection via the selector lever lock Number
solenoid is interrupted. The locking pin of the
solenoid for the ignition key removal inhibitor 1 - Current selector lever posi-
does not engage in the ignition lock. The tion
ignition key can be turned to "0" and removed 2 - Engaged gear
from the ignition lock.
Function
• In all other selector lever positions the ground
connection is made via the selector lever lock • The instrument cluster indicates the current
solenoid. The locking pin of the solenoid for selector lever position or the engaged gear
the ignition key removal inhibitor engages in (Select-Shift mode) to the driver. This signal
the ignition lock. It is not possible to turn the is transmitted from the transmission control
ignition key to "0" and remove it from the unit via the CAN databus .
ignition lock. • In selector lever position "P", the instrument
Consequences of component failure cluster also receives a signal from the
• A short to ground will make it impossible to selector lever lock solenoid confirming
remove the ignition key from the ignition lock. whether the selector lever is actually in "P".
• A break in the electrical circuit will make it • The instrument cluster performs a plausibility
possible to remove the ignition key from the check with this signal and does not display
ignition lock in all selector lever positions. "P" (for reasons of safety) until both signals
from the transmission control unit and the
selector lever lock solenoid are present.
Instrument Cluster Consequences of component failure
• The instrument cluster cannot display the
selector lever position or the engaged gear if
the signals are not received via the CAN
databus.
• If the connection to the selector lever lock
solenoid is interrupted then "P" is not
displayed.

GEM

Installation position.
• The GEM is located in the passenger
compartment underneath the glove
compartment.
Function
• In conjunction with the automatic
transmission, the GEM warns the driver with
a warning tone if the selector lever is not in
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307-01B-60 Automatic Transmission/Transaxle — Vehicles With: 307-01B-60

5-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

position "P" and the ignition key is turned to
position "1". The GEM receives the
information whether or not the selector lever
is in position "P" from the selector lever lock
solenoid.
Consequences of component failure
• If the connection is interrupted then the GEM
will not give out a warning tone.

Backup lamp relay

Installation position.
• The backup lamp relay is located in the
central junction box (CJB).
Function
• The backup lamp relay receives a signal from
the TR sensor if the selector lever position
"R" is engaged, and then switches on the
backup lamps.
Consequences of component failure
• If the connection to the TR sensor is
interrupted then the backup lamps will not be
switched on.

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307-01B-61 Automatic Transmission/Transaxle — Vehicles With: 307-01B-61
5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

Diagnostic Trouble Code Charts
DIAGNOSIS AND TESTING

Condition Possible Sources Action

• P0701 Transmission fluid tem- • Automatic transmission fluid • REFER to WDS.
perature circuit error temperature sensor.
• Circuit(s).
• P0705 Transmission range (TR) • Inhibitor switch circuit(s). • REFER to WDS.
sensor error
• P0715 Turbine speed sensor • Turbine speed sensor. • REFER to WDS.
(TSS) error
• P0720 Output shaft speed • Output shaft speed sensor. • REFER to WDS.
(OSS) sensor
• P0725 Engine revolution speed • Powertrain control module. • REFER to WDS.
error • Circuit(s).
• P0731 Gear ratio 1 incorrect • Incorrect transmission fluid • Carry out the transmission fluid
level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect transmission fluid con- • Carry out the transmission fluid
dition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.
• Incorrect throttle signal. • Go to Pinpoint Test A.
• Line pressure is low.
• Control valve error.
• Reduction one-way clutch error.
• Low clutch error.
• Low one-way clutch error.
• P0732 Gear ratio 2 incorrect • Incorrect transmission fluid • Carry out the transmission fluid
level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect transmission fluid con- • Carry out the transmission fluid
dition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.
• Incorrect throttle signal. • Go to Pinpoint Test B.
• Vehicle speed sensor (VSS)
short/open/disconnected.
• Line pressure is high.
• Line pressure is low.
• Control valve error.
• 2-4 Duty solenoid
short/open/disconnected.
• Reduction one-way clutch error.
• Low clutch error.
• 2-4 Brake and servo error.

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307-01B-62 Automatic Transmission/Transaxle — Vehicles With: 307-01B-62

5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• P0733 Gear ratio 3 incorrect • Incorrect transmission fluid • Carry out the transmission fluid
level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect transmission fluid con- • Carry out the transmission fluid
dition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.
• Incorrect throttle signal. • Go to Pinpoint Test C.
• Vehicle speed sensor (VSS)
short/open/disconnected.
• Line pressure is high.
• Line pressure is low.
• Control valve error.
• High clutch error
(burn/stick/slip).
• Reduction one-way clutch error.
• Low clutch error.
• 2-4 Brake and servo error.
• P0734 Gear ratio 4 incorrect • Incorrect transmission fluid • Carry out the transmission fluid
level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect transmission fluid con- • Carry out the transmission fluid
dition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.
• Incorrect throttle signal. • Go to Pinpoint Test D.
• Vehicle speed sensor (VSS)
short/open/disconnected.
• Line pressure is high.
• Line pressure is low.
• Control valve error.
• 2-4 Duty solenoid
short/open/disconnected.
• High clutch error
(burn/stick/slip).
• Reduction one-way clutch error.
• Low clutch error.
• 2-4 Brake and servo error.
• P0735 Gear ratio 5 incorrect • Incorrect transmission fluid • Carry out the transmission fluid
level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect transmission fluid con- • Carry out the transmission fluid
dition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.

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307-01B-63 Automatic Transmission/Transaxle — Vehicles With: 307-01B-63
5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Incorrect throttle signal. • Go to Pinpoint Test E.
• Vehicle speed sensor (VSS)
short/open/disconnected.
• Line pressure is high.
• Line pressure is low.
• Control valve error.
• High clutch error
(burn/stick/slip).
• Direct clutch error
(burn/stick/slip).
• P0743 Lock-up duty/torque con- • Lock-up duty solenoid. • REFER to WDS.
verter clutch solenoid failure • Circuit(s).
• P0745 Pressure control solenoid • Line pressure duty solenoid. • REFER to WDS.
A electrical • Circuit(s).
• P0750 Shift solenoid A • Shift solenoid A. • REFER to WDS.
• Circuit(s).
• P0760 Shift solenoid B • Shift solenoid B. • REFER to WDS.
• Circuit(s).
• P0765 Shift solenoid C • Shift solenoid C. • REFER to WDS.
• Circuit(s).
• P0778 2/4 Brake duty solenoid • 2/4 Brake duty solenoid. • REFER to WDS
• Circuit(s).
• P0799 Intermediate speed sen- • Intermediate speed sensor. • REFER to WDS.
sor • Circuit(s).
• P0800 Timing solenoid A • Neutral shift timing solenoid. • REFER to WDS.
• Circuit(s).
• P0801 Timing solenoid B • Reduction timing solenoid. • REFER to WDS.
• Circuit(s).
• P0802 Pressure control solenoid • 2/4 Brake duty solenoid. • REFER to WDS.
B • Circuit(s).
• P0803 Pressure control solenoid • High clutch pressure duty • REFER to WDS.
C solenoid.
• Circuit(s).
• P0804 Lock-up clutch error • Incorrect automatic transmission • Carry out the transmission fluid
fluid level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect automatic transmission • Carry out the transmission fluid
fluid condition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.

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307-01B-64 Automatic Transmission/Transaxle — Vehicles With: 307-01B-64

5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Incorrect throttle signal. • Go to Pinpoint Test F.
• Vehicle speed sensor (VSS)
short/open/disconnected.
• Engine speed sensor
short/open/disconnected.
• Automatic transmission fluid
temperature sensor
short/open/disconnected.
• Control valve error.
• Lock-up solenoid
short/open/disconnected.
• Torque converter error
(burn/stick/slip).
• P805 Torque reduction error • Powertrain control module • REFER to WDS.
request (PCM).
• Circuit(s).
• P0806 Module ignition supply • Ignition voltage out of range (8 – • REFER to WDS.
input error 18v).
• P0808 Manual switches • Incorrect pattern. • REFER to WDS.
• P0809 Gear ratio R incorrect • Incorrect transmission fluid • Carry out the transmission fluid
level. level check. REFER to Trans-
mission Fluid Level Check in
this section.
• Incorrect transmission fluid con- • Carry out the transmission fluid
dition. condition check. REFER to
Transmission Fluid Drain and
Refill in this section.
• Inhibitor switch "N" position is • Adjust the "N" position using the
out of adjustment. special tool.
• Line pressure is low. • Go to Pinpoint Test G.
• Control valve error.
• Reverse clutch error
(burn/stick/slip).
• Low and reverse brake error
(burn/stick/slip).
• P0810 CAN Communication bus • CAN bus. • REFER to WDS.
error
• P0812 Torque reduction error • Powertrain control module • REFER to WDS.
(PCM).
• Circuit(s).
• P1603 EEPROM failure • Circuit(s). • REFER to WDS.
• Transmission control module
(TCM).
• P1710 Transmission control • Circuit(s). • REFER to WDS.
module (TCM) ground return
electrical check

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307-01B-65 Automatic Transmission/Transaxle — Vehicles With: 307-01B-65
5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• P1745 Low clutch timing sole- • Low clutch timing solenoid. • REFER to WDS.
noid • Circuit(s).
• P1746 Reduction timing sole- • Reduction timing solenoid. • REFER to WDS.
noid • Circuit(s).
• P1747 2/4 Brake timing solenoid • 2/4 Brake duty solenoid. • REFER to WDS.
• Circuit(s).
• P1777 Torque reduction error • Reported engine failure. • REFER to WDS.
• P1791 Throttle angle error • Powertrain control module • REFER to WDS.
(PCM).
• Circuit(s).
• P1793 Module ignition supply • Ignition Voltage out of range (8 • REFER to WDS.
input error – 18v).
• P1796 CAN Communication bus • CAN bus. • REFER to WDS.
error
• P1797 CAN EMS error • CAN bus. • REFER to WDS.

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307-01B-66 Automatic Transmission/Transaxle — Vehicles With: 307-01B-66
5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

Diagnostic Strategy

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
• Damaged shift • Fuse(s)
mechanism • Electrical connec-
• Transaxle fluid tor(s)
leaks
• Damaged transaxle
casing
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 cause is not visually evident, verify the
symptom and refer to WDS.

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307-01B-67 Automatic Transmission/Transaxle — Vehicles With: 307-01B-67
5-Speed Automatic Transaxle

GENERAL PROCEDURES
Transmission Fluid Level Check
GENERAL PROCEDURES

CAUTION: If a new transmission fluid 7. WARNING: Make sure that the parking
cooler has been installed, make sure that brake control lever is in the fully
the active bypass valve was open, before applied position. Failure to follow this
checking the transmission fluid level. instruction may result in personal
The active bypass valve opens at a injury.
temperature above 77°C.
Move the transmission range selector
1. NOTE: Make sure that the transaxle is not in lever through all the gear ranges, allowing
emergency run operation. sufficient time for each position to engage.
Connect the diagnostic tool to the data link 8. Move the transmission range selector
connector (DLC). lever to the "P" (PARK) position.
9. When the transmission fluid temperature
reaches 30°C, move the transmission
range selector lever from "P" (PARK)
position to "D" (DRIVE) position and back
to "P" (PARK) position.
10. CAUTION: Make sure that the
transmission range selector lever is in
the "P" (PARK) position.
Raise and support the vehicle. For
additional information, refer to Section
100-02.
11. NOTE: The transmission fluid temperature
must be between 35°C and 45°C.
2. Check that the transmission fluid Check the transmission fluid
temperature is below 30°C. temperature.
3. Raise and support the vehicle. For
additional information, refer to Section 12. WARNING: Whenever releasing the
100-02. transmission fluid, take care to
4. Remove the selector lever cable cover. prevent scalding. Failure to follow this
instruction may result in personal
injury.
Remove the test plug.
• Allow the fluid to drain into a suitable
container.
• Discard the test plug seal.

5. Lower the vehicle.

6. Start the engine.

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307-01B-68 Automatic Transmission/Transaxle — Vehicles With: 307-01B-68

5-Speed Automatic Transaxle

GENERAL PROCEDURES (Continued)

13. WARNING: Whenever releasing the 20. Install the selector lever cable cover.
transmission fluid, take care to
prevent scalding. Failure to follow this
instruction may result in personal
injury.
NOTE: Transmission fluid should escape from
the test outlet.
Check for escaping transmission fluid.
14. If no transmission fluid escapes, fill the
transaxle with transmission fluid. For
additional information, refer to
Transmission Fluid Drain and Refill in
this section.
15. NOTE: Install a new test plug seal.
Install the test plug. 21. Lower the vehicle.

16. Lower the vehicle.

17. Switch off the engine.
18. Disconnect the diagnostic tool from the
DLC.
19. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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307-01B-69 Automatic Transmission/Transaxle — Vehicles With: 307-01B-69
5-Speed Automatic Transaxle

GENERAL PROCEDURES
Transmission Fluid Drain and Refill

1. Remove the transaxle oil filler tube plug.

4. NOTE: Install a new drain plug seal.
NOTE: Clean the drain plug thread.
Install the drain plug.

2. Raise and support the vehicle. For

additional information, refer to Section
100-02.
3. NOTE: If an internal transaxle concern is 5. Lower the vehicle.
suspected, drain the fluid through a paper 6. Fill the transaxle with automatic
filter. A small amount of metal or friction transmission fluid . For additional
particles may be found from normal wear. information, refer to Specifications in this
However, if excessive metal or friction section.
particles are present, a detailed inspection of 7. Install the transaxle oil filler tube plug.
the transaxle will be required.
Drain the transaxle.
• Allow the fluid to drain into a suitable
container.
• Discard the drain plug seal.

8. Check the transmission fluid level. For

additional information, refer to
Transmission Fluid Level Check in this
section.

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307-01B-70 Automatic Transmission/Transaxle — Vehicles With: 307-01B-70
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter
IN-VEHICLE REPAIR

All vehicles
4. Disconnect the transaxle electrical con-
nectors and detach the wiring harness
Special Tool(s)
from the wiring harness bracket.
Separator, Oil Pan
303-428 (21-179)

Name Specification
Metal Surface Cleaner WSE-M5B-392-A
Sealer WSS-M4G320-A3

Removal
All vehicles 5. Remove the transaxle wiring harness
1. Disconnect the battery ground cable. For bracket from the transaxle.
additional information, refer to Section • Detach the fluid cooler pipes from the
414-01. bracket.
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with diesel engine
3. Remove the charge air cooler intake hose.

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307-01B-71 Automatic Transmission/Transaxle — Vehicles With: 307-01B-71
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

6. NOTE: Plug the fluid cooler pipes to prevent oil 8. CAUTION: Do not damage the
loss or dirt ingress. transaxle fluid pan.
Detach the fluid cooler pipes from the Using the special tool, remove the
transaxle. transaxle fluid pan.
• Allow the fluid to drain into a suitable con- • Slide the special tool around the profile of
tainer. the pan.

7. Remove the fluid pan retaining bolts.

Installation
All vehicles
1. NOTE: Make sure that the fluid pan and
transaxle case mating faces are clean and oil
free.
Clean all mating faces using metal surface
cleaner.
2. Apply a 5 mm diameter bead of sealer to
the inside edge of the fluid pan mating
face.

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307-01B-72 Automatic Transmission/Transaxle — Vehicles With: 307-01B-72

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

3. NOTE: Tighten the fluid pan retaining bolts 5. Install the transaxle wiring harness bracket
evenly working diagonally. to the transaxle.
Install the fluid pan. • Attach the fluid cooler pipes to the bracket.

6. Attach the transaxle wiring harness to the

wiring harness bracket and connect the
transaxle electrical connectors.

4. Attach the fluid cooler pipes to the trans-

axle.

Vehicles with diesel engine

7. Install the charge air cooler intake hose.

All vehicles
8. Lower the vehicle.

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307-01B-73 Automatic Transmission/Transaxle — Vehicles With: 307-01B-73
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

9. Fill the transaxle with automatic
transmission fluid. For additional
information, refer to Transmission Fluid
Drain and Refill in this section.
10. Connect the battery ground cable. For
additional information, refer to Section
414-01.
11. Check the transmission fluid level. For
additional information, refer to
Transmission Fluid Level Check in this
section.
12. Initialize the door window motors. For
additional information, refer to Section
501-11.

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307-01B-74 Automatic Transmission/Transaxle — Vehicles With: 307-01B-74
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Halfshaft Seal LH (14 303 0)
2. Loosen the strut and spring assembly top
mount nuts by four turns.
Special Tool(s)
Slide Hammer
205-047 (15-011)

Remover, Torque Converter

Oil Seal
307-272 (17-061)

Installer, Differential Double

Lip Oil Seal 3. Remove the subframe. For additional
information, refer to Section 502-00.
308-203 (16-066)
4. CAUTION: Support the halfshaft. The
inner joint must not be bent more than
18 degrees. The outer joint must not
Remover, Halfshaft be bent more than 45 degrees.
308-256 (16-089) Using the special tool, detach the left-hand
halfshaft from the transaxle and secure it
to one side.
• Discard the O-ring seal.
• Remove and discard the snap ring.
Name Specification
Grease WSD-M1C230-A

Removal
1. Remove the strut and spring assembly top
mount brace cover.

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307-01B-75 Automatic Transmission/Transaxle — Vehicles With: 307-01B-75
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

5. Using the special tools, remove the 2. CAUTION: Support the halfshaft. The
halfshaft oil seal. inner joint must not be bent more than
• Allow the oil to drain into a suitable con- 18 degrees. The outer joint must not
tainer. be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
CAUTION: Make sure the snap ring is
correctly seated.
CAUTION: Lubricate the O-ring seal with
grease.
NOTE: Install a new O-ring seal.
NOTE: Install a new snap ring.
Attach the halfshaft to the transaxle.

Installation
1. Using the special tool, install the halfshaft
oil seal.

3. Install the subframe. For additional

information, refer to Section 502-00.
4. Tighten the strut and spring assembly top
mount nuts.

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307-01B-76 Automatic Transmission/Transaxle — Vehicles With: 307-01B-76

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

5. Install the strut and spring assembly top
mount brace cover.

6. Check the transmission fluid level. For

additional information, refer to
Transmission Fluid Level Check in this
section.

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307-01B-77 Automatic Transmission/Transaxle — Vehicles With: 307-01B-77
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Halfshaft Seal RH (14 304 0)
2. Loosen the strut and spring assembly top
mount nuts by four turns.
Special Tool(s)
Slide Hammer
205-047 (15-011)

Remover, Torque Converter

Oil Seal
307-272 (17-061)

Installer, Differential Double

Lip Oil Seal 3. Remove the subframe. For additional
information, refer to Section 502-00.
308-203 (16-066)
Vehicles with diesel engine
4. CAUTION: Support the halfshaft. The
inner joint must not be bent more than
Name Specification 18 degrees. The outer joint must not
be bent more than 45 degrees.
Grease WSD-M1C230-A
Detach the right-hand halfshaft and the
intermediate shaft from the transaxle and
secure it to one side.
Removal
• Remove and discard the center bearing
All vehicles cap and locknuts.
1. Remove the strut and spring assembly top • Discard the O-ring seal.
mount brace cover.

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307-01B-78 Automatic Transmission/Transaxle — Vehicles With: 307-01B-78

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

Vehicles with 2.5L engine Installation
5. CAUTION: Support the halfshaft. The All vehicles
inner joint must not be bent more than 1. Using the special tool, install the halfshaft
18 degrees. The outer joint must not oil seal.
be bent more than 45 degrees.
Detach the right-hand halfshaft and the
intermediate shaft from the transaxle and
secure it to one side.
• Remove and discard the locknuts.
• Discard the O-ring seal.

Vehicles with 2.5L engine

2. CAUTION: Support the halfshaft. The
inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.

All vehicles CAUTION: Do not damage the halfshaft

6. Using the special tools, remove the oil seal.
halfshaft oil seal.
CAUTION: Lubricate the O-ring seal with
• Allow the oil to drain into a suitable con- grease.
tainer.
NOTE: Install a new O-ring seal.
NOTE: Install new locknuts.
Attach the right-hand halfshaft and the in-
termediate shaft to the transaxle.

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307-01B-79 Automatic Transmission/Transaxle — Vehicles With: 307-01B-79
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

Vehicles with diesel engine 6. Install the strut and spring assembly top
mount brace cover.
3. CAUTION: Support the halfshaft. The
inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
CAUTION: Lubricate the O-ring seal with
grease.
NOTE: Install a new O-ring seal.
NOTE: Install a new center bearing cap and
locknuts.
Attach the right-hand halfshaft and the in-
termediate shaft to the transaxle.
7. Check the transmission fluid level. For
additional information, refer to
Transmission Fluid Level Check in this
section.

All vehicles
4. Install the subframe. For additional
information, refer to Section 502-00.
5. Tighten the strut and spring assembly top
mount nuts.

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307-01B-80 Automatic Transmission/Transaxle — Vehicles With: 307-01B-80
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Transmission Range (TR) Sensor (17 705 0)
5. Remove the battery tray support bracket
lower retaining bolts and detach the wiring
harnesses.
Special Tool(s)
1. Remove the bolts.
Alignment Gauge TR Sensor 2. Detach the ground cables from the battery
307-438 (17–087) tray support bracket.
• Detach the wiring harness from the battery
tray support bracket.

Removal
1. Move the selector lever to the "D" (DRIVE)
position.
2. Remove the battery. For additional
information, refer to Section 414-01.
3. Remove the battery tray.
• Remove the clips.

6. Remove the battery tray support bracket.

4. Detach the central junction box (CJB) from

the battery tray and position to one side.

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307-01B-81 Automatic Transmission/Transaxle — Vehicles With: 307-01B-81
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

7. Remove the transmission range (TR) 2. NOTE: Make sure the transaxle is in the "N"
sensor. (NEUTRAL) position.
• Disconnect the electrical connector. Using the special tool, align the TR sensor
• Remove the bolts. and tighten the retaining bolts.

3. Remove the special tool.

Installation 4. Install the battery tray support bracket.

1. NOTE: Do not fully tighten the transmission

range (TR) sensor retaining bolts at this stage.
Install the TR sensor.
• Connect the electrical connector.
• Install the bolts.

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307-01B-82 Automatic Transmission/Transaxle — Vehicles With: 307-01B-82

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

5. Install the battery tray support bracket
8. Install the battery. For additional
lower retaining bolts and attach the wiring
information, refer to Section 414-01.
harnesses.
9. Check the transaxle for correct operation.
1. Install the bolts.
• With the parking brake applied the engine
2. Attach the ground cables to the battery tray
should start only in "P" (PARK) or "N"
support bracket.
(NEUTRAL). Reversing lamps should
• Attach the wiring harness to the battery illuminate only when "R" (REVERSE) is
tray support bracket. selected.
10. Initialize the door window motors. For
additional information, refer to Section
501-11.

6. Attach the central junction box (CJB) to

the battery tray.

7. Install the battery tray.

• Install the clips.

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307-01B-83 Automatic Transmission/Transaxle — Vehicles With: 307-01B-83
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Main Control Valve Body

Removal
3. CAUTION: Only remove the indicated
1. Remove the fluid pan. For additional bolts.
information, refer to Fluid Pan, Gasket and
CAUTION: Make sure the manual valve
Filter in this section.
remains in place while removing the
2. Disconnect the transaxle electrical main control valve body.
connectors.
NOTE: The indicated bolts are colored silver.
1. Disconnect the transaxle wiring harness
electrical connector. Remove the main control valve body.
2. Disconnect the solenoid valves electrical • Remove the bolts.
connector.
• Detach the wiring harness from the main
control valve body.

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307-01B-84 Automatic Transmission/Transaxle — Vehicles With: 307-01B-84

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

4. Remove the transaxle case O-ring seals. 3. Move the manual valve to the indicated
• Discard the O-ring seals. position as shown.

4. NOTE: Make sure that the O-ring seals are

correctly seated.
Installation
NOTE: Make sure that the manual valve is
1. NOTE: Install new transaxle case O-ring seals. located in the manual valve lever groove.
NOTE: Do not tighten the main control valve
Install the transaxle case O-ring seals.
body retaining bolts at this stage.
Position the main control valve body and
loosely install two retaining bolts.

2. Move the manual valve detent lever into

position "1".

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307-01B-85 Automatic Transmission/Transaxle — Vehicles With: 307-01B-85
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

5. Check the function and the position of the 7. Connect the transaxle electrical
manual valve. connectors.
• Rotate the manual valve detent lever 1. Connect the transaxle wiring harness
through all positions. electrical connector.
• Move the manual valve detent lever into 2. Connect the solenoid valves electrical
position "2" and check the indicated posi- connector.
tion in the main control valve body. • Attach the wiring harness to the main con-
trol valve body.

6. Install the remaining main control valve

body retaining bolts.
• The length of the bolt indicated is 105.5
mm.

8. Install the fluid pan. For additional

information, refer to Fluid Pan, Gasket and
Filter in this section.

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307-01B-86 Automatic Transmission/Transaxle — Vehicles With: 307-01B-86
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Solenoids - Shift, TCC and EPC

Removal 2. Disconnect the shift solenoid electrical

connectors.
NOTE: This procedure covers all solenoids
1. Disconnect the shift solenoid A electrical
contained in the main control valve body.
connector (colored brown).
1. Remove the main control valve body. For
additional information, refer to Main 2. Disconnect the torque converter clutch
Control Valve Body in this section. (TCC) solenoid electrical connector
(colored white).
3. Disconnect the reduction solenoid electrical
connector (colored white).
4. Disconnect the low clutch timing solenoid
electrical connector (colored white).
5. Disconnect the shift solenoid B electrical
connector (colored brown).
6. Disconnect the shift solenoid C electrical
connector (colored green).
7. Disconnect the second, third and fourth
gear brake duty solenoid electrical
connector (colored white).
8. Disconnect the neutral shift solenoid
electrical connector (colored black).
9. Disconnect the electronic pressure control
(EPC) solenoid electrical connector (col-
ored green).

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307-01B-87 Automatic Transmission/Transaxle — Vehicles With: 307-01B-87
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

3. Remove the shift solenoid A. 6. Remove the low clutch timing solenoid.

4. Remove the TCC solenoid. 7. Remove the shift solenoid B.

5. Remove the reduction timing solenoid. 8. Remove the shift solenoid C.

• Remove the TCC solenoid retaining
bracket.

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307-01B-88 Automatic Transmission/Transaxle — Vehicles With: 307-01B-88

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

9. Remove the second, third and fourth gear Installation
brake duty solenoid.
1. NOTE: Install all new components supplied
with the service kit.
To install, reverse the removal procedure.

10. Remove the neutral shift solenoid.

• Remove the second, third and fourth gear
brake duty solenoid bracket.

11. Remove the EPC solenoid.

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307-01B-89 Automatic Transmission/Transaxle — Vehicles With: 307-01B-89
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR
Transmission Control Module (TCM)

Removal 4. Remove the air duct from the heater core

and evaporator housing.
1. Remove the instrument panel. For
additional information, refer to Section
501-12.
2. Locally detach the left-hand front scuff
plate from the inner sill panel.

5. Remove the defroster duct.

3. Detach the central junction box (CJB) from

the A-pillar and position it to one side.

6. Disconnect the temperature blend door

and the air distribution blend door actuator
electrical connectors.
• Detach the wiring harness.

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307-01B-90 Automatic Transmission/Transaxle — Vehicles With: 307-01B-90

5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

7. Disconnect the blower motor and blower 10. Disconnect the in-car entertainment elec-
motor resistor electrical connectors. trical connector.

8. Disconnect the parking brake warning 11. Detach the telematics control module
indicator switch electrical connector. from the cross-vehicle beam.
• Depress the tang. • Detach the clamp.

9. Disconnect the air bag control module 12. Disconnect the auto-dimming interior
electrical connectors. mirror and interior lamp electrical con-
• Detach the wiring harness. nectors.

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307-01B-91 Automatic Transmission/Transaxle — Vehicles With: 307-01B-91
5-Speed Automatic Transaxle

IN-VEHICLE REPAIR (Continued)

13. Remove the cross-vehicle beam. Installation
• Detach the wiring harness.
1. CAUTION: Make sure that the correct
transmission control module (TCM) is
installed or irregular driving
conditions may occur.
NOTE: Install new rivets.
To install, reverse the removal procedure.

14. Disconnect the transmission control

module (TCM) electrical connectors.
• Locally detach the insulation pad.

15. Remove the TCM.

• Remove and discard the rivets.

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307-01B-92 Automatic Transmission/Transaxle — Vehicles With: 307-01B-92
5-Speed Automatic Transaxle

REMOVAL
Transaxle — 2.0L Diesel (17 214 0)
REMOVAL

2. Remove the battery tray.

• Remove the clips.
Special Tool(s)
Support Bar, Engine
303-290A (21-140)

Adapter for 303-290A

303–290–01 (21–140–01)

Adapter for 303-290A

3. Remove the engine upper cover.
303-290-02 (21-140-02)
• Remove the oil level indicator.

Adapter for 303-290A

303-290-03A (21-140-03A)

Remover, Halfshaft
308-256 (16-089)

4. Remove the strut and spring assembly top

mount brace cover on both sides.
General Equipment
Securing straps
Transmission jack
1. Remove the battery. For additional
information, refer to Section 414-01.

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307-01B-93 Automatic Transmission/Transaxle — Vehicles With: 307-01B-93
5-Speed Automatic Transaxle

REMOVAL (Continued)
5. Loosen the strut and spring assembly top 8. Raise and support the vehicle. For
mount nuts by four turns on both sides. additional information, refer to Section
100-02.
9. Remove the selector lever cable cover.

6. Disconnect the mass air flow (MAF) sensor

electrical connector.
10. NOTE: Make sure the transaxle selector lever
is in the "D" (DRIVE) position.
Detach the selector lever cable from the
selector shaft lever.
1. Detach the selector lever cable from the
selector shaft lever pin.
2. Detach the selector lever cable from the
selector lever cable bracket.

7. Remove the air cleaner.

1. Disconnect the air cleaner intake pipe.
2. Disconnect the positive crankcase
ventilation (PCV) hose.
3. Disconnect the turbocharger air intake
pipe.
4. Disconnect the vacuum hose.

11. Remove the subframe. For additional

information, refer to Section 502-00.

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307-01B-94 Automatic Transmission/Transaxle — Vehicles With: 307-01B-94

5-Speed Automatic Transaxle

REMOVAL (Continued)

12. Remove the charge air cooler intake 14. CAUTION: Support the halfshaft. The
hose. inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
Using the special tool, detach the left-
hand halfshaft from the transaxle and
secure it to one side.
• Discard the snap ring.
• Discard the O-ring seal.

13. CAUTION: Support the halfshaft. The

inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
Detach the right-hand halfshaft and the
intermediate shaft from the transaxle and
secure it to one side.
• Remove and discard the center bearing 15. Detach the heater pipe from the trans-
cap and locknuts. axle.
• Discard the O-ring seal.

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307-01B-95 Automatic Transmission/Transaxle — Vehicles With: 307-01B-95
5-Speed Automatic Transaxle

REMOVAL (Continued)
16. Remove the torque converter retaining 20. Disconnect the crankshaft position (CKP)
nuts. sensor electrical connector.
• Remove the cover.
• Rotate the engine to gain access to the
nuts.
• Discard the nuts.

21. Detach the ground cable from the trans-

axle.

17. Lower the vehicle.

18. Disconnect the vent hose from the trans-
axle.

22. Remove the transaxle left-hand upper re-

taining bolt.

19. Detach the cable bracket from the trans-

axle.

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307-01B-96 Automatic Transmission/Transaxle — Vehicles With: 307-01B-96

5-Speed Automatic Transaxle

REMOVAL (Continued)
23. Remove the transaxle right-hand upper 26. Remove the engine rear mount.
retaining bolt. • Discard the center nut.
• Detach the vacuum reservoir bracket.

27. Remove the engine rear mount bracket.

24. Remove the bulkhead cover.

28. Raise and support the vehicle. For

25. Install the special tools. additional information, refer to Section
100-02.
29. NOTE: Plug the fluid cooler pipes to prevent
oil loss or dirt ingress.
Disconnect the fluid cooler pipes from
the transaxle.
• Allow the fluid to drain into a suitable con-
tainer.

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307-01B-97 Automatic Transmission/Transaxle — Vehicles With: 307-01B-97
5-Speed Automatic Transaxle

REMOVAL (Continued)

33. WARNING: Make sure the torque

30. Disconnect the transaxle electrical con-
converter remains in the torque
nectors.
converter housing.
NOTE: Use a suitable wooden block to protect
the transaxle.
NOTE: Secure the transaxle with securing straps.
Using a suitable transmission jack re-
move the transaxle.

31. Remove the transaxle right-hand retain-

ing bolts.

34. NOTE: Make a note of the position of the

dowel pins in the engine flange, to aid
installation.
Lower the transaxle.

32. Remove the transaxle left-hand and lower

retaining bolts.

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307-01B-98 Automatic Transmission/Transaxle — Vehicles With: 307-01B-98
5-Speed Automatic Transaxle

REMOVAL
Transaxle — 2.5L (17 214 0)
2. Remove the battery tray.

Special Tool(s)
Support Bar, Engine
303-290A (21-140)

Adapter for 303-290A

303–290–01 (21–140–01)

3. Remove the engine upper cover.

Adapter for 303-290A
303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Adapter for 303-290A

303-290-05A (21-140-05A)
4. Remove the strut and spring assembly top
mount brace cover on both sides.

Remover, Halfshaft
308-256 (16-089)

General Equipment
Securing straps
Transmission jack
1. Remove the battery. For additional
information, refer to Section 414-01.

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307-01B-99 Automatic Transmission/Transaxle — Vehicles With: 307-01B-99
5-Speed Automatic Transaxle

REMOVAL (Continued)
5. Loosen the strut and spring assembly top 8. Remove the starter motor.
mount nuts by four turns on both sides.

9. Raise and support the vehicle. For

6. Remove the air cleaner. additional information, refer to Section
1. Disconnect the positive crankcase 100-02.
ventilation (PCV) hoses. 10. Remove the selector lever cable cover.
2. Disconnect the mass air flow (MAF) sensor
electrical connector.
3. Disconnect the air cleaner intake hose.

7. Disconnect the starter motor electrical

connectors.

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307-01B-100 Automatic Transmission/Transaxle — Vehicles With: 307-01B-100

5-Speed Automatic Transaxle

REMOVAL (Continued)
14. CAUTION: Support the halfshaft. The
11. NOTE: Make sure the transaxle selector lever inner joint must not be bent more than
is in "D" (DRIVE) position. 18 degrees. The outer joint must not
Detach the selector lever cable from the be bent more than 45 degrees.
selector shaft lever.
CAUTION: Do not damage the halfshaft
1. Detach the selector lever cable from the oil seal.
selector shaft lever pin.
NOTE: Plug the transaxle to prevent oil loss or
2. Detach the selector lever cable from the dirt ingress.
selector lever cable bracket.
Using the special tool, detach the left-
hand halfshaft from the transaxle and
secure it to one side.
• Discard the snap ring.
• Discard the O-ring seal.

12. Remove the subframe. For additional

information, refer to Section 502-00.
13. CAUTION: Support the halfshaft. The
inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees. 15. Remove the torque converter retaining
nuts.
CAUTION: Do not damage the halfshaft • Remove the cover.
oil seal. • Rotate the engine to gain access to the
NOTE: Plug the transaxle to prevent oil loss or nuts.
dirt ingress. • Discard the nuts.
Detach the right-hand halfshaft and the
intermediate shaft from the transaxle and
secure it to one side.
• Remove and discard the locknuts.
• Discard the O-ring seal.

16. Lower the vehicle.

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307-01B-101 Automatic Transmission/Transaxle — Vehicles With: 307-01B-101
5-Speed Automatic Transaxle

REMOVAL (Continued)
17. Disconnect the vent hose from the trans- 20. Remove the bulkhead cover.
axle.

21. Install the special tools.

18. Detach the ground cable from the trans-
axle.

22. Remove the engine rear mount.

• Discard the center nut.
19. Remove the transaxle upper retaining
bolts.

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307-01B-102 Automatic Transmission/Transaxle — Vehicles With: 307-01B-102

5-Speed Automatic Transaxle

REMOVAL (Continued)
23. Remove the engine rear mount bracket.
27. Remove the transaxle right-hand retain-
ing bolts.

24. Raise and support the vehicle. For

additional information, refer to Section
28. Remove the transaxle left-hand retaining
100-02.
bolts.
25. NOTE: Plug the fluid cooler pipes to prevent
oil loss or dirt ingress.
Disconnect the fluid cooler pipes from
the transaxle.
• Allow the fluid to drain into a suitable con-
tainer.

29. Remove the transaxle lower retaining

bolts.

26. Disconnect the transaxle electrical con-

nectors.

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307-01B-103 Automatic Transmission/Transaxle — Vehicles With: 307-01B-103
5-Speed Automatic Transaxle

REMOVAL (Continued)

30. WARNING: Make sure the torque

converter remains in the torque
converter housing.
NOTE: Use a suitable wooden block to protect
the transaxle.
NOTE: Secure the transaxle with securing straps.
Using a suitable transmission jack re-
move the transaxle.

31. NOTE: Make a note of the position the dowel

pins in the engine flange, to aid installation.
Lower the transaxle.

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307-01B-104 Automatic Transmission/Transaxle — Vehicles With: 307-01B-104
5-Speed Automatic Transaxle

INSTALLATION
Transaxle — 2.0L Diesel (17 214 0)
INSTALLATION

2. CAUTION: The torque converter hub

must engage fully in the oil pump
Special Tool(s) drive gear.

Support Bar, Engine Check the installation depth of the torque

converter.
303-290A (21-140)
1. Lay a steel straight edge across the
transaxle flange.
2. Check the installation depth between the
steel straight edge and the drive plate stud.
Adapter for 303-290A
303-290-01 (21-140-01)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

General Equipment
Securing straps
Transmission jack
Steel straight edge

Name Specification
Grease WSD-M1C230-A

1. CAUTION: The torque converter hub

must remain at the correct installation
depth throughout the whole
installation procedure.
NOTE: The torque converter studs must be
aligned with the engine drive plate holes before
any transaxle bolts are installed.
Install the torque converter.

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307-01B-105 Automatic Transmission/Transaxle — Vehicles With: 307-01B-105
5-Speed Automatic Transaxle

INSTALLATION (Continued)

3. CAUTION: The torque converter must 6. Tighten the transaxle right-hand retaining
remain at the correct installation bolts.
depth throughout the entire
installation procedure.
NOTE: Secure the transaxle with securing straps.
NOTE: Use a suitable wooden block to protect
the transaxle.
NOTE: Make sure that the dowel pins are
correctly installed in the engine flange.
Using a suitable transmission jack install
the transaxle.

7. Connect the transaxle electrical connec-

tors.

4. Remove the securing straps.

5. Tighten the transaxle left-hand and lower
retaining bolts.

8. NOTE: Install new torque converter retaining

nuts.
Install the torque converter retaining nuts.
• Rotate the engine to gain access to the
nuts.
• Install the cover.

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307-01B-106 Automatic Transmission/Transaxle — Vehicles With: 307-01B-106

5-Speed Automatic Transaxle

INSTALLATION (Continued)
9. Attach the heater pipe to the transaxle. 13. NOTE: Install a new engine rear mount
center retaining nut.
Install the engine rear mount.

10. Connect the fluid cooler pipes to the

transaxle.
14. Remove the special tools.

11. Lower the vehicle.

12. Install the engine rear mount bracket. 15. Install the bulkhead cover.

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307-01B-107 Automatic Transmission/Transaxle — Vehicles With: 307-01B-107
5-Speed Automatic Transaxle

INSTALLATION (Continued)
16. Install the transaxle right-hand upper 19. Connect the crankshaft position (CKP)
retaining bolts. sensor electrical connector.
• Attach the vacuum reservoir bracket.

20. Attach the cable bracket to the transaxle.

17. Install the transaxle left-hand upper re-
taining bolt.

21. Connect the vent hose to the transaxle.

18. Attach the ground cable to the transaxle.

22. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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307-01B-108 Automatic Transmission/Transaxle — Vehicles With: 307-01B-108

5-Speed Automatic Transaxle

INSTALLATION (Continued)

23. CAUTION: Support the halfshaft. The 24. CAUTION: Support the halfshaft. The
inner joint must not be bent more than inner joint must not be bent more than
18 degrees. The outer joint must not 18 degrees. The outer joint must not
be bent more than 45 degrees. be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft CAUTION: Do not damage the halfshaft
oil seal. oil seal.
CAUTION: Make sure the snap ring is CAUTION: Lubricate the O-ring seal with
correctly seated. grease.
NOTE: Install a new O-ring seal.
CAUTION: Lubricate the O-ring seal with
grease. NOTE: Install a new center bearing cap and new
locknuts.
NOTE: Install a new O-ring seal.
NOTE: Install a new snap ring. Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
Attach the left-hand halfshaft to the
transaxle.

25. Install the charge air cooler intake hose.

26. Install the subframe. For additional

information, refer to Section 502-00.

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307-01B-109 Automatic Transmission/Transaxle — Vehicles With: 307-01B-109
5-Speed Automatic Transaxle

INSTALLATION (Continued)
27. NOTE: Make sure the transaxle selector lever 31. Install the air cleaner.
is in the "D" (DRIVE) position. 1. Connect the air cleaner intake pipe.
Attach the selector lever cable to the 2. Connect the positive crankcase ventilation
selector shaft lever. (PCV) hose.
1. Attach the selector lever cable to the 3. Connect the turbocharger air intake pipe.
selector lever cable bracket. 4. Connect the vacuum hose.
2. Attach the selector lever cable to the selec-
tor shaft lever pin.

32. Connect the mass air flow (MAF) sensor

electrical connector.
28. Open the yellow locking clip on the select
lever cable adjustment mechanism.

33. Tighten the strut and spring assembly

top mount nuts on both sides.
29. Adjust the selector lever cable. For
additional information, refer to Section
307-05A / 307-05B.
30. Lower the vehicle.

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307-01B-110 Automatic Transmission/Transaxle — Vehicles With: 307-01B-110

5-Speed Automatic Transaxle

INSTALLATION (Continued)

34. Install the strut and spring assembly top 38. CAUTION: If a new transaxle is being
mount brace cover on both sides. installed, a new transmission fluid oil
cooler and new transmission fluid
cooler tubes must be installed.
Install a new transmission fluid cooler
and new transmission fluid cooler tubes
if necessary. For additional information,
refer to Section 307-02A / 307-02B.
39. Fill the transaxle.
40. NOTE: Only carry out the following step when
a new transaxle has been installed.
Using worldwide diagnostic system
(WDS), reset the transmission control
module (TCM).
41. Initialize the door window motors. For
35. Install the engine upper cover. additional information, refer to Section
• Install the oil level indicator. 501-11.

36. Install the battery tray.

• Install the clips.

37. Install the battery. For additional

information, refer to Section 414-01.

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307-01B-111 Automatic Transmission/Transaxle — Vehicles With: 307-01B-111
5-Speed Automatic Transaxle

INSTALLATION
Transaxle — 2.5L (17 214 0)
2. CAUTION: The torque converter hub
must engage fully in the oil pump
Special Tool(s) drive gear.

Support Bar, Engine Check the installation depth of the torque

converter.
303-290A (21-140A)
1. Lay a steel straight edge across the
automatic transaxle flange.
2. Check the installation depth between the
steel straight edge and the drive plate stud.
Adapter for 303-290A
303-290-01 (21-140-01)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Adapter for 303-290A

303-290-05A (21-140-05A)

General Equipment
Securing straps
Transmission jack
Steel straight edge

Name Specification
Grease WSD-M1C230-A

1. CAUTION: The torque converter must

remain at the correct installation
depth throughout the whole
installation procedure.
NOTE: The torque converter studs must be
aligned with the engine drive plate holes before
any transaxle bolts are installed.
Install the torque converter.

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307-01B-112 Automatic Transmission/Transaxle — Vehicles With: 307-01B-112

5-Speed Automatic Transaxle

INSTALLATION (Continued)

3. CAUTION: The torque converter must 6. Install the transaxle left-hand retaining
remain at the correct installation bolts.
depth throughout the entire
installation procedure.
NOTE: Secure the transaxle with securing straps.
NOTE: Use a suitable wooden block to protect
the transaxle.
NOTE: Make sure that the dowel pins are
correctly installed in the engine flange.
Using a suitable transmission jack, install
the transaxle.

7. Install the transaxle right-hand retaining

bolts.

4. Remove the securing straps.

5. Install the transaxle lower retaining bolts.

8. Connect the transaxle electrical connec-

tors.

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307-01B-113 Automatic Transmission/Transaxle — Vehicles With: 307-01B-113
5-Speed Automatic Transaxle

INSTALLATION (Continued)
9. NOTE: Install new torque converter retaining 13. NOTE: Install a new engine rear mount
nuts. center retaining nut.
Install the torque converter retaining nuts. Install the engine rear mount.
1. Rotate the engine to gain access to the
nuts.
2. Install the cover.

14. Remove the special tools.

10. Connect the fluid cooler pipes to the

transaxle.

15. Install the bulkhead cover.

11. Lower the vehicle.

12. Install the engine rear mount bracket.

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307-01B-114 Automatic Transmission/Transaxle — Vehicles With: 307-01B-114

5-Speed Automatic Transaxle

INSTALLATION (Continued)

16. Tighten the transaxle upper retaining 20. CAUTION: Support the halfshaft. The
bolts. inner joint must not be bent more than
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
CAUTION: Make sure the snap ring is
correctly seated.
CAUTION: Lubricate the O-ring seal with
grease.
NOTE: Install a new O-ring seal.
NOTE: Install a new snap ring.
Attach the left-hand halfshaft to the
transaxle.
17. Attach the ground cable to the transaxle.

18. Connect the vent hose to the transaxle.

19. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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307-01B-115 Automatic Transmission/Transaxle — Vehicles With: 307-01B-115
5-Speed Automatic Transaxle

INSTALLATION (Continued)

21. CAUTION: Support the halfshaft. The

24. Open the yellow locking clip on the selec-
inner joint must not be bent more than
tor lever cable adjustment mechanism.
18 degrees. The outer joint must not
be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft
oil seal.
CAUTION: Lubricate the O-ring seal with
grease.
NOTE: Install a new O-ring seal.
NOTE: Install new locknuts.
Attach the right-hand front drive halfshaft
and the intermediate shaft to the trans-
axle.

25. Adjust the selector lever cable. For

additional information, refer to Section
307-05A / 307-05B.
26. Lower the vehicle.
27. Install the starter motor.

22. Install the subframe. For additional

information, refer to Section 502-00.
23. NOTE: Make sure the transaxle selector lever
is in the "D" (DRIVE) position.
Connect the selector lever cable to the
selector shaft lever.
1. Attach the selector lever cable to the
28. Connect the starter motor electrical con-
selector lever cable bracket.
nectors.
2. Attach the selector lever cable to the selec-
tor shaft lever pin.

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307-01B-116 Automatic Transmission/Transaxle — Vehicles With: 307-01B-116

5-Speed Automatic Transaxle

INSTALLATION (Continued)

29. Install the air cleaner. 32. Install the engine upper cover.
1. Connect the air cleaner intake hose.
2. Connect the positive crankcase ventilation
(PCV) hoses.
3. Connect the mass air flow (MAF) sensor
electrical connector.

33. Install the battery tray.

30. Tighten the strut and spring assembly

top mount nuts on both sides.

34. Install the battery. For additional

information, refer to Section 414-01.
35. CAUTION: If a new transaxle is being
installed, a new transmission fluid oil
cooler and new transmission fluid
cooler tubes must be installed.
31. Install the strut and spring assembly top
mount brace cover on both sides. Install a new transmission fluid cooler
and new transmission fluid cooler tubes
if necessary. For additional information,
refer to Section 307-02A / 307-02B.
36. Fill the transaxle. For additional
information, refer to Transmission Fluid
Drain and Refill in this section.
37. NOTE: Only carry out the following step when
a new transaxle has been installed.
Using worldwide diagnostic system
(WDS), reset the transmission control
module (TCM).

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307-01B-117 Automatic Transmission/Transaxle — Vehicles With: 307-01B-117
5-Speed Automatic Transaxle

INSTALLATION (Continued)
38. Initialize the door window motors. For
additional information, refer to Section
501-11.

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307-02A-1 Transmission/Transaxle Cooling 307-02A-1

SECTION 307-02A Transmission/Transaxle Cooling

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 307-02-2

DESCRIPTION AND OPERATION

Transaxle Cooling.............................................................................................................. 307-02-3

REMOVAL AND INSTALLATION

Transmission Fluid Cooler ............................................................................ (17 834 0) 307-02-4

Transmission Fluid Cooler Tubes ................................................................. (17 857 0) 307-02-6

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307-02A-2 Transmission/Transaxle Cooling — Vehicles With: 307-02A-2
4-Speed Automatic Transaxle

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Automatic transmission fluid ESP-M2C166-H

Torque Specifications
Description Nm lb-ft lb-in
Feed and return tube – automatic transmission 23 17 –
fluid cooler

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307-02A-3 Transmission/Transaxle Cooling — Vehicles With: 307-02A-3
4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

Transaxle Cooling
DESCRIPTION AND OPERATION

System overview for the 2.0L engine

Item Part Description

Number
1 - Feed line
2 - Return line
3 - Transmission fluid cooler

The transmission fluid cooler is located in front of

the engine coolant radiator and is fitted by means
of two bolts.

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307-02A-4 Transmission/Transaxle Cooling — Vehicles With: 307-02A-4
4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Transmission Fluid Cooler (17 834 0)
REMOVAL AND INSTALLATION

4. WARNING: Whenever releasing the

transaxle cooling system fluid, take
Name Specification care to prevent fluid scalding. Failure
to follow these instructions may result
Automatic transmission ESP-M2C166-H in personal injury.
fluid
CAUTION: Plug the fluid cooler tubes to
prevent fluid loss or dirt ingress.
Removal NOTE: Mark the position of the feed and return
hose.
1. Remove the front bumper. For additional NOTE: Collect escaping fluid using a drain pan.
information, refer to Section 501-19.
Disconnect the feed and return hose from
2. Raise and support the vehicle. For
the transmission fluid cooler.
additional information, refer to Section
100-02.
3. Remove the clips and the left-hand cover.

5. Remove the transmission fluid cooler.

• Lift the cooler off the bracket.

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307-02A-5 Transmission/Transaxle Cooling — Vehicles With: 307-02A-5
4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

Installation 6. Check the transmission fluid level. For
additional information, refer to Section
1. Install the transmission fluid cooler. 307-01A / 307-01B.
• Push the cooler into the bracket holes.

2. NOTE: Position marks.

Connect the feed and the return hose to
the transmission fluid cooler.

3. Install the clips and the left-hand cover.

4. Lower the vehicle.

5. Install the front bumper. For additional
information, refer to Section 501-19.

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307-02A-6 Transmission/Transaxle Cooling — Vehicles With: 307-02A-6
4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Transmission Fluid Cooler Tubes (17 857 0)
3. CAUTION: Prevent the fluid pipe
adapter from turning using an open
Name Specification end spanner, do not remove it from
the transaxle housing.
Automatic transmission ESP-M2C166-H
fluid Detach the fluid cooler return pipe from
the transaxle.
• Close off the openings using suitable
Removal plugs.

1. WARNING: Whenever releasing the

transaxle cooling system fluid, take
care to prevent fluid scalding. Failure
to follow these instructions may result
in personal injury.
NOTE: Plug the fluid cooler tubes to prevent fluid
loss and dirt ingress.
Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. NOTE: Mark the positions of the feed and
return hose.
NOTE: Collect escaping fluid in a drain pan.
4. CAUTION: Prevent the fluid pipe
Disconnect the feed and return hose from adapter from turning using an open
the transmission fluid cooler. end spanner, do not remove it from
the transaxle housing.
Detach the fluid cooler pipe from the
transaxle.
• Detach the fluid pipe bracket from the
transaxle.
• Close off the openings using suitable
plugs.

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307-02A-7 Transmission/Transaxle Cooling — Vehicles With: 307-02A-7
4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

Installation 3. NOTE: Position marks.
Connect the feed and return hose to the
1. CAUTION: Prevent the fluid pipe
transaxle.
adapter from turning using an open
end spanner, do not remove it from 1. Connect the feed tube.
the transaxle housing. 2. Connect the return tube.
Attach the fluid cooler pipe to the
transaxle.
• Attach the fluid pipe bracket to the trans-
axle.

4. Lower the vehicle.

5. Check the transmission fluid level. For
additional information, refer to Section
307-01A / 307-01B.
2. CAUTION: Prevent the fluid pipe
adapter from turning using an open
end spanner, do not remove it from
the transaxle housing.
Attach the fluid cooler return pipe to the
transaxle.

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307-02B-1 Transmission/Transaxle Cooling 307-02B-1

SECTION 307-02B Transmission/Transaxle Cooling

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 307-02-2

REMOVAL AND INSTALLATION

Transmission Fluid Cooler — 2.5L................................................................ (17 834 0) 307-02-3

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307-02B-2 Transmission/Transaxle Cooling — Vehicles With: 307-02B-2
5-Speed Automatic Transaxle

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Specifications
Automatic transmission fluid WSS-M2C922-A1

Torque Specifications
Item Nm lb-ft lb-in
Transmission fluid cooler 10 - 89

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307-02B-3 Transmission/Transaxle Cooling — Vehicles With: 307-02B-3
5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Transmission Fluid Cooler — 2.5L (17 834 0)
REMOVAL AND INSTALLATION

Removal 5. Remove the left-hand duct (front bumper

cover shown removed for clarity).
1. Remove the radiator grille.

2. Remove the transmission fluid cooler re- 6. WARNING: Whenever releasing the
taining bolts. transaxle cooling system fluid, take
care to prevent fluid scalding. Failure
to follow these instructions may result
in personal injury.
CAUTION: Plug the fluid cooler tubes to
prevent fluid loss or dirt ingress.
NOTE: Mark the position of the feed and return
hose.
Disconnect the feed and return hose from
the transmission fluid cooler.
• Allow the fluid to drain into a suitable con-
tainer.

3. Raise and support the vehicle. For

additional information, refer to Section
100-02.
4. Remove the radiator undershield.

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307-02B-4 Transmission/Transaxle Cooling — Vehicles With: 307-02B-4

5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

7. Remove the transmission fluid cooler.
3. Install the left-hand duct (front bumper
• Lift the transmission fluid cooler off the cover shown removed for clarity).
bracket.

4. Install the radiator undershield.

Installation
1. Install the transmission fluid cooler.
• Push the transmission fluid cooler into the
bracket holes.

5. Lower the vehicle.

6. Install the transmission fluid cooler retain-
ing bolts.

2. NOTE: Position marks.

Connect the feed and the return hose to
the transmission fluid cooler.

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307-02B-5 Transmission/Transaxle Cooling — Vehicles With: 307-02B-5
5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

7. CAUTION: If a new transmission fluid

cooler has been installed, make sure
that the active bypass valve was open,
before checking the transmission fluid
level. The active bypass valve opens
at a temperature above 77 °C.
Check the transmission fluid level. For
additional information, refer to Section
307-01A / 307-01B.

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307-05A-1 Automatic Transmission/Transaxle External Controls 307-05A-1

SECTION 307-05A Automatic

Transmission/Transaxle External Controls
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 307-05-2

DESCRIPTION AND OPERATION

External Controls............................................................................................................... 307-05-3

Selector lever ................................................................................................................... 307-05-3
Selector lever lock ............................................................................................................ 307-05-3
Overdrive inhibitor button ................................................................................................. 307-05-3
Selector lever lock button ................................................................................................. 307-05-4

DIAGNOSIS AND TESTING

External Controls............................................................................................................... 307-05-5

GENERAL PROCEDURES

Selector Lever Cable Adjustment ...................................................................................... 307-05-6

REMOVAL AND INSTALLATION

Selector Lever Cable ......................................................................................................... 307-05-8

Transmission Selector Lever ............................................................................................. 307-05-14

DISASSEMBLY AND ASSEMBLY

Selector Lever ................................................................................................................... 307-05-16

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307-05A-2 Automatic Transmission/Transaxle External Controls 307-05A-2
— Vehicles With: 4-Speed Automatic Transaxle

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Grease SM-1C1021-A

Torque Specifications
Description Nm lb-ft lb-in
Selector lever knob bolt 1 – 9
Selector lever cable grommet 9 – 80
Selector lever assembly 9 – 80

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307-05A-3 Automatic Transmission/Transaxle External Controls 307-05A-3
— Vehicles With: 4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION

External Controls
DESCRIPTION AND OPERATION

The selector cable assembly must be renewed as

a complete unit.
Selector lever
Position Description
P PARK
WARNING: Only engage when the vehicle is stationary.
PARK should be engaged during repairs on a running
engine. The selector lever can only be moved out of the
"P" position if the ignition key is in position II and the
footbrake is depressed. In an emergency (discharged
battery) it can also be released manually - see selector
lever lock.
For securing the vehicle. The engine can be started.
R REVERSE Only engage when the vehicle is stationary and the engine is
idling.
N NEUTRAL The engine can be started - no power transfer to the drive
wheels.
D First to fourth gear Normal driving position. All four gears are shifted electronically.
(with overdrive) Driving with and without overdrive - see overdrive inhibitor but-
ton.
D First to third gear Normal driving position, but no fourth gear. Driving with and
(without overdrive) without overdrive - see overdrive inhibitor button.
2 Second gear The transmission stays in second gear.
1 First gear The transmission stays in first gear.
1. Remove the cover.
Selector lever lock 2. Using the ignition key, depress the release
lever.
3. Shift the selector lever out of position "P".

Overdrive inhibitor button

NOTE: Returning the selector lever to "P"

immobilizes the selector lever again.
It is possible to release the selector lever
immobiliser mechanically from position "P" if for
example the battery is drained or disconnected.
The overdrive function (suppression of gearshifts
into fourth gear) can be switched on or off by the
inhibitor button on the selector lever knob. The
corresponding indicator lamp in the instrument
G37628 en 08/2002 2003.0 Mondeo
307-05A-4 Automatic Transmission/Transaxle External Controls 307-05A-4

— Vehicles With: 4-Speed Automatic Transaxle

DESCRIPTION AND OPERATION (Continued)

panel lights up showing that the overdrive
function is switched off.
To activate the overdrive function, press the
button and the lamp will extinguish.

Selector lever lock button

To move the selector lever out of "P"

• Set ignition switch to position II
• Apply the foot brake
• Depress the lock button on the selector lever
and shift the lever out of "P".
The lock button needs to be depressed when
shifting from "R" to "P", from "N" to "R" and from
"D" to "2".

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307-05A-5 Automatic Transmission/Transaxle External Controls 307-05A-5
— Vehicles With: 4-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

External Controls
DIAGNOSIS AND TESTING

Since troubleshooting starts as soon as the

vehicle is taken in for repair, the following Visual Inspection Chart
procedure is recommended: Electrical
1. Check customer concern is clear. If – Check connections for seating and corrosion.
necessary, reproduce the concern on the – Battery not connected.
vehicle. 3. If the concern can be clearly identified during
2. If the concern cannot be reconstructed, a visual check, rectify the concern and test
perform a test drive and/or carry out a visual the proper operation of the system.
check with the aid of the following table: 4. If it cannot be clearly determined, use the
symptom chart below to locate the source of
Visual Inspection Chart the concern.
Mechanical
WARNING: Danger of an accident. Apply
– Visibly damaged or worn parts. the parking brake. Shift the automatic
– Loose or missing screws or nuts. transmission to position "P".
Condition Possible Sources Action
• Selector lever lock perminently • Selector lever lock cannot be • Check the relevant electric
locked. operated. components and circuits by
– Battery flat. means of circuit diagrams.
– Steering column lock/ignition
switch not in position "II" and
foot brake not depressed.
– Fuse F24 in the central
junction box (CJB) faulty.
– Fuse F23 in the CJB faulty.
– Instrument interface module
- no power supply.
• Solenoid (on the selector lever) • Check the relevant electric
not functioning. components and circuits by
means of circuit diagrams.
• Selector lever lock not function- • Selector cable adjusted incor- • Adjust the selector cable (see
ing. rectly. relevant subsection).
• Mechanical damage to the se- • Repair the selector cable (see
lector lever. relevant subsection).
• Selector lever position display • Faulty adjustment of the selector • Adjust the selector cable (see
does not line up with the gear cable. relevant subsection).
that is engaged.
• The selector lever assembly is • Release the selector lever as-
not in alignment with the cover. sembly from the floor assembly
and adjust.
• The selector lever cannot be • Incorrect adjustment of the se- • Adjust the selector cable (see
shifted into position "P" or "1". lector cable. relevant subsection).
• Mechanical fault on the selector • Remove the selector lever and
lever repair.

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307-05A-6 Automatic Transmission/Transaxle External Controls 307-05A-6
— Vehicles With: 4-Speed Automatic Transaxle

GENERAL PROCEDURES
Selector Lever Cable Adjustment
GENERAL PROCEDURES

3. Raise and support the vehicle. For

additional information, refer to Section
Adjustment 100-02.
1. Shift selector lever to position ""D”. 4. Rotate the manual valve detent lever
assembly to the ""D” position.
1. Low 1
2. Low 2
3. Drive
4. Neutral
5. Reverse
6. Park

2. NOTE: Make sure the selector lever cable

outer sleeve is free for moving after unlocking.
Open the selector lever cable locking
mechanism (turn counterclockwise).

5. Lower the vehicle.

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307-05A-7 Automatic Transmission/Transaxle External Controls 307-05A-7
— Vehicles With: 4-Speed Automatic Transaxle

GENERAL PROCEDURES (Continued)

6. Close the selector lever cable outer sleeve
by turning the locking mechanism clock-
wise.

7. Check the selector lever cable adjustment.

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307-05A-8 Automatic Transmission/Transaxle External Controls 307-05A-8
— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Selector Lever Cable
REMOVAL AND INSTALLATION

Removal 3. Detach the selector lever cable from the

transaxle.
1. Detach the positive crankcase ventilation
(PCV) hose and the vacuum hose from the 1. Detach the selector lever cable.
engine upper cover. 2. Remove the selector lever cable from the
bracket.

2. Remove the engine upper cover.

4. Unclip the selector lever cable from the
brake pipe.

5. Raise and support the vehicle. For

additional information, refer to Section
100-02.

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307-05A-9 Automatic Transmission/Transaxle External Controls 307-05A-9
— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

6. Remove the catalytic converter heat 11. Remove the floor console side trim
shield. panels.
• Detach the catalyst monitor sensor wiring 1. Remove the retaining bolt.
harness. 2. Detach the retaining clips.

7. Detach the selector lever cable from the 12. Unclip the selector lever cable retaining
bracket. clip from the selector.

8. Lower the vehicle. 13. Remove the selector lever cable from the
9. Move the selector lever to the ""N” selector lever.
position. • Pull the retaining pin and push out the se-
10. Remove the selector lever trim panel. lector lever cable.

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307-05A-10 Automatic Transmission/Transaxle External Controls 307-05A-10

— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

14. Lift the floor carpet and the insulator ma- 17. Detach the air pipe (selector lever re-
terial and position it to one side. moved shown).

15. Remove the selector lever cable grom- 18. NOTE: Before pulling through the selector
met. lever cable, tie a guide wire to the selector
lever cable transaxle end.
Remove the selector lever cable from the
front.

Installation
1. NOTE: Tie the selector lever cable to the
pulled-in wire and pull the selector lever cable
into position.
Install the selector lever cable to the front.
2. Attach the air pipe (selector lever removed
shown).

16. Remove the air pipe screw and raise the

air pipe until the stop.

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307-05A-11 Automatic Transmission/Transaxle External Controls 307-05A-11
— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

3. Push down the air pipe until the stop and 6. Install the selector lever cable to the
install the air pipe screw. selector lever.
• Pull the retaining pin and push in the selec-
tor lever cable.

4. Install the selector lever cable grommet.

7. Clip the selector lever cable retaining clip

into the selector.

5. Secure the insulator material and the floor

carpet with adhesive straps.

8. Install the floor console side trim panels.

1. Detach the retaining clips.
2. Remove the retaining bolt.

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307-05A-12 Automatic Transmission/Transaxle External Controls 307-05A-12

— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

9. Clip in the selector gate cover. 14. Clip the selector lever cable to the brake
• Install the selector lever trim panel. pipe.

10. Raise and support the vehicle. For 15. Attach the selector lever cable to the
additional information, refer to Section transaxle.
100-02. 1. Install the selector lever cable to the
11. Attach the selector lever cable to the bracket.
bracket. 2. Attach the selector lever cable.

12. Install the catalytic converter heat shield. 16. Install the engine upper cover.
• Attach the catalyst monitor sensor wiring
harness.

13. Lower the vehicle.

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307-05A-13 Automatic Transmission/Transaxle External Controls 307-05A-13
— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

17. Attach the PCV hose and the vacuum
hose to the engine upper cover.

18. Adjust the selector lever cable. For

additional information, refer to Selector
Lever Cable Adjustment in this section.

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307-05A-14 Automatic Transmission/Transaxle External Controls 307-05A-14
— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Transmission Selector Lever

Removal
1. Move the selector lever to the ""N” 5. Remove the selector lever cable from the
position. selector lever.
2. Remove the selector lever trim panel. • Pull the retaining pin and push out the se-
lector lever cable.

3. Remove the floor console side trim panels.

6. Detach the selector lever cable retaining
1. Remove the retaining bolt.
clip from the selector lever.
2. Detach the retaining clips.

7. Disconnect the selector lever electrical

4. Detach the selector lever cable retaining connector.
clip from the selector.

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307-05A-15 Automatic Transmission/Transaxle External Controls 307-05A-15
— Vehicles With: 4-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

Installation
8. Raise and support the vehicle. For
additional information, refer to Section 1. To install, reverse the removal procedure.
100-02.
9. Remove the catalytic converter heat
shield.
• Detach the catalyst monitor sensor wiring
harness.

10. Remove the selector lever retaining nuts.

11. Lower the vehicle.

12. Remove the selector lever.

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307-05A-16 Automatic Transmission/Transaxle External Controls 307-05A-16
— Vehicles With: 4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY

Selector Lever
DISASSEMBLY AND ASSEMBLY

3. Remove the selector lever knob.

• Remove the screw.
Name Specification
Grease SM-1C1021-A

Disassembly
1. Remove the selector lever shift lock sole-
noid cover.

4. Remove the selector lever plunger.

2. Disconnect the overdrive (O/D) switch

electrical connector.

5. Turn the socket counter-clockwise and de-

tach the socket and lamp.

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307-05A-17 Automatic Transmission/Transaxle External Controls 307-05A-17
— Vehicles With: 4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY (Continued)

6. Remove the selector lever upper cover. 2. Install the selector lever upper cover (four
• Depress the four retaining lugs. retaining lugs).

7. Remove the selector lever lower cover. 3. Attach the socket and lamp and turn the
socket clockwise.
1. Depress the two retaining lugs.

4. Install the selector lever plunger.

Assembly
1. Install the selector lever lower cover (two
retaining lugs).

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307-05A-18 Automatic Transmission/Transaxle External Controls 307-05A-18

— Vehicles With: 4-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY (Continued)

5. 5. Install the selector lever knob.
• Install the screw.

6. Connect the O/D switch electrical connec-

tor.

7. Install the selector lever shift lock solenoid

cover.

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307-05B-1 Automatic Transmission/Transaxle External Controls 307-05B-1

SECTION 307-05B Automatic

Transmission/Transaxle External Controls
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 307-05-2

DIAGNOSIS AND TESTING

External Controls............................................................................................................... 307-05-3

Inspection and Verification ............................................................................................... 307-05-3

GENERAL PROCEDURES

Selector Lever Cable Adjustment ...................................................................................... 307-05-5

REMOVAL AND INSTALLATION

Selector Lever Cable ......................................................................................................... 307-05-7

Transmission Selector Lever ............................................................................................. 307-05-12

DISASSEMBLY AND ASSEMBLY

Selector Lever ................................................................................................................... 307-05-14

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307-05B-2 Automatic Transmission/Transaxle External Controls 307-05B-2
— Vehicles With: 5-Speed Automatic Transaxle

SPECIFICATIONS

Torque Specifications
Item Nm lb-ft lb-in
Selector lever knob retaining bolt 1 - 9
Selector lever cable grommet 9 - 80
Selector lever assembly 9 - 80
Selector lever cable cover retaining bolts 22 16 -

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307-05B-3 Automatic Transmission/Transaxle External Controls 307-05B-3
— Vehicles With: 5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING

External Controls
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 307-05 for Mechanical Electrical

schematic and connector information.
• Visibly damaged or • Fuse(s)
worn components • Electrical
Inspection and Verification • Loose or missing connector(s)
nuts or bolts. • Selector lever lock
WARNING: Make sure the vehicle road switch
wheels are chocked and the parking
3. If an obvious cause for an observed or
brake is applied before carrying out this
reported concern is found, correct the cause
procedure. Failure to follow this
(if possible) before proceeding to the next
instruction may result in personal injury.
step.
1. Verify the customer concern.
4. If the cause is not visually evident, verify the
2. Visually inspect for obvious signs of symptom and refer to the Symptom Chart.
mechanical and electrical damage.

Visual Inspection Chart

Condition Possible Sources Action
NOTE: The selector lever immobilizer can be released mechanically from the "P" (PARK) position, if for
example the battery is drained or disconnected.
• Selector lever locked in the "P" • Brake pedal switch. • CHECK the brake pedal switch
(PARK) position. and circuit(s). REFER to Wiring
Diagrams.
• Selector lever lock solenoid. • CHECK the selector lever lock
solenoid and circuit(s). REFER
to Wiring Diagrams.
• Selector lever cable. • CHECK the selector lever cable
operation and adjustment.
REFER to Selector Lever Cable
/ Selector Lever Cable Adjust-
ment in this section.
• Selector Lever • DISASSEMBLE the selector
lever and INSTALL new compo-
nent as necessary. REFER to
Selector Lever in this section.
• Selector lever does not lock. • Selector lever lock solenoid. • CHECK the selector lever lock
solenoid and circuit(s). REFER
to Wiring Diagrams.
• Selector lever cable adjustment. • ADJUST the selector lever ca-
ble. REFER to Selector Lever
Cable Adjustment in this sec-
tion.
• Selector lever. • DISASSEMBLE the selector
lever and INSTALL new compo-
nent as necessary. REFER to
Selector Lever in this section.

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307-05B-4 Automatic Transmission/Transaxle External Controls 307-05B-4

— Vehicles With: 5-Speed Automatic Transaxle

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Instrument cluster selector lever • Selector lever cable adjustment. • ADJUST the selector lever ca-
position indicator does not dis- ble. REFER to Selector Lever
play the correct selector lever Cable Adjustment in this sec-
position. tion.
• Instrument Cluster. • CHECK the instrument cluster.
REFER to WDS.
• "P" (PARK) or "D" (DRIVE) can- • Selector lever cable adjustment. • ADJUST the selector lever ca-
not be selected. ble. REFER to Selector Lever
Cable Adjustment in this sec-
tion.
• Selector lever. • DISASSEMBLE the selector
lever and INSTALL new compo-
nent as necessary. REFER to
Selector Lever in this section.
• Transaxle internal failure. • REFER to Section 307-01A /
307-01B.

G88814 en 08/2002 2003.0 Mondeo

307-05B-5 Automatic Transmission/Transaxle External Controls 307-05B-5
— Vehicles With: 5-Speed Automatic Transaxle

GENERAL PROCEDURES
Selector Lever Cable Adjustment
GENERAL PROCEDURES

1. Shift the selector lever to the "D" (DRIVE)

5. NOTE: The dot on the transaxle housing must
position.
align with the hole on the manual control lever
when in the "D" (DRIVE) position.
Rotate the manual control lever to the "D"
(DRIVE) position.
1. "P" (PARK) position.
2. "R" (REVERSE) position.
3. "N" (NEUTRAL) position.
4. "D" (DRIVE) position.

2. Raise and support the vehicle. For

additional information, refer to Section
100-02.
3. Remove the selector lever cable cover.

6. NOTE: Make sure that the selector lever cable

adjustment mechanism is locked.
Fully depress the yellow selector lever ca-
ble locking clip.

4. Open the yellow locking clip of the selec-

tor lever cable adjustment mechanism.

7. Lower the vehicle.

8. NOTE: If any gear range fails to select, repeat
the procedure.
Start the engine and move the
transmission selector lever through all of
the gear ranges, allowing sufficient time
for each range to engage.

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307-05B-6 Automatic Transmission/Transaxle External Controls 307-05B-6

— Vehicles With: 5-Speed Automatic Transaxle

GENERAL PROCEDURES (Continued)

9. Shift the transmission selector lever to the
"P" (PARK) position and switch OFF the
engine.
10. Raise and support the vehicle. For
additional information, refer to Section
100-02.
11. Install the selector lever cable cover.

G88815 en 08/2002 2003.0 Mondeo

307-05B-7 Automatic Transmission/Transaxle External Controls 307-05B-7
— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Selector Lever Cable
REMOVAL AND INSTALLATION

Removal Vehicles with diesel engine

5. Remove the insulation pad.
All vehicles
1. Shift the selector lever to the "D" (DRIVE)
position.

All vehicles
6. Remove the selector lever cable cover.
2. Remove the floor console. For additional
information, refer to Section 501-12.
3. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with 2.5L engine
4. Remove the catalytic converter heat
shield.
• Detach the catalyst monitor sensor wiring
harness.

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307-05B-8 Automatic Transmission/Transaxle External Controls 307-05B-8

— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

7. NOTE: Make sure the transaxle selector lever 10. Remove the selector lever cable from the
is in the "D" (DRIVE) position. selector lever.
Detach the selector lever cable from the • Pull the retaining pin and push out the se-
selector shaft lever. lector lever cable.
1. Detach the selector lever cable from the
selector shaft lever pin.
2. Detach the selector lever cable from the
selector lever cable bracket.

11. Lift the floor carpet and the insulation

material and position it to one side.

8. Lower the vehicle.

9. Detach the selector lever cable retaining
clip from the selector.

12. Remove the selector lever cable grom-

met.

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307-05B-9 Automatic Transmission/Transaxle External Controls 307-05B-9
— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

13. Remove the air pipe screw and raise the Installation
air pipe to the stop.
All vehicles
1. Install the selector lever cable (selector
lever shown removed for clarity).

14. Detach the air pipe (selector lever shown

removed for clarity).

2. Attach the air pipe (selector lever shown

removed for clarity).

15. Remove the selector lever cable (selector

lever shown removed for clarity).

3. Push down the air pipe to the stop and in-

stall the air pipe screw.

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307-05B-10 Automatic Transmission/Transaxle External Controls 307-05B-10

— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

4. Install the selector lever cable grommet. 7. Attach the selector lever cable retaining
clip into the selector.

5. Secure the insulation material and the

floor carpet with adhesive strips. 8. Install the floor console. For additional
information, refer to Section 501-12.
9. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with 2.5L engine
10. Install the catalytic converter heat shield.
• Attach the catalyst monitor sensor wiring
harness.

6. Install the selector lever cable to the

selector lever.
• Pull the retaining pin and push in the selec-
tor lever cable.

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307-05B-11 Automatic Transmission/Transaxle External Controls 307-05B-11
— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

Vehicles with diesel engine
14. Adjust the selector lever cable. For
11. Install the insulation pad.
additional information, refer to Section
307-05A / 307-05B.
15. Install the selector lever cable cover.

All vehicles
12. Open the yellow locking clip on the select
lever cable adjustment mechanism.
16. Lower the vehicle.

13. NOTE: Make sure the transaxle selector lever

is in the "D" (DRIVE) position.
Attach the selector lever cable to the
selector shaft lever.
1. Attach the selector lever cable to the
selector lever cable bracket.
2. Attach the selector lever cable to the selec-
tor shaft lever pin.

G88823 en 08/2002 2003.0 Mondeo

307-05B-12 Automatic Transmission/Transaxle External Controls 307-05B-12
— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION

Transmission Selector Lever

Removal 5. Detach the selector lever cable retaining

clip from the selector lever.
All vehicles
1. Shift the selector lever to the "D" (DRIVE)
position.
2. Remove the selector lever adapter ring.

6. Remove the selector lever cable from the

selector lever.
• Pull the retaining pin and push out the se-
lector lever cable.
3. Remove the selector lever trim panel.

7. Detach the selector lever cable retaining

4. Remove the floor console. For additional clip from the selector lever.
information, refer to Section 501-12.

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307-05B-13 Automatic Transmission/Transaxle External Controls 307-05B-13
— Vehicles With: 5-Speed Automatic Transaxle

REMOVAL AND INSTALLATION (Continued)

8. Disconnect the selector lever electrical All vehicles
connector. 12. Remove the selector lever retaining nuts.

9. Raise and support the vehicle. For 13. Lower the vehicle.
additional information, refer to Section 14. Remove the selector lever.
100-02.
Vehicles with 2.5L engine
10. Remove the catalytic converter heat
shield.
• Detach the catalyst monitor sensor wiring
harness.

Installation
1. To install, reverse the removal procedure.
2. Adjust the selector lever cable. For
additional information, refer to Section
Vehicles with diesel engine 307-05A / 307-05B.
11. Remove the insulation pad.

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307-05B-14 Automatic Transmission/Transaxle External Controls 307-05B-14
— Vehicles With: 5-Speed Automatic Transaxle

DISASSEMBLY AND ASSEMBLY

Selector Lever
DISASSEMBLY AND ASSEMBLY

Disassembly 4. Remove the selector lever lower cover.

1. Remove the transaxle selector lever cover. • Depress the two retaining lugs.

2. Remove the selector lever knob.

• Remove the retaining bolt. Assembly
1. To assemble, reverse the disassembly
procedure.

3. Remove the selector lever upper cover.

G203999 en 08/2002 2003.0 Mondeo

309-00-1 Exhaust System 309-00-1

SECTION 309-00 Exhaust System

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 309-00-2

DESCRIPTION AND OPERATION

Exhaust System ................................................................................................................ 309-00-3

Vehicles with 1.8L and 2.0L engine .................................................................................. 309-00-3
Vehicles with 2.5L engine................................................................................................. 309-00-4
Vehicles with Diesel engine .............................................................................................. 309-00-5

REMOVAL AND INSTALLATION

Dual Converter Y-Pipe.................................................................................. (25 002 0) 309-00-6

Catalytic Converter — 1.8L/2.0L................................................................... (25 250 0) 309-00-8
Catalytic Converter — 2.5L........................................................................... (25 250 0) 309-00-10
Exhaust Flexible Pipe ................................................................................... (25 004 0) 309-00-12

08/2002 2003.0 Mondeo

309-00-2 Exhaust System 309-00-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Lubricant ESE-M99B144-B
Anti-seize grease SAM-1C907-A

Torque Specifications
Description Nm lb-ft lb-in
Exhaust flexible pipe to exhaust manifold nuts 46 34 –
Exhaust flexible pipe to catalytic converter nuts 46 34 –
Exhaust flexible pipe to front muffler pipe nuts 46 34 –
Exhaust flexible pipe to catalytic converter clamp 55 41 –
nuts – Vehicles with 3.0L engine
Exhaust flexible pipe support bracket retaining nut 10 – 89
– Vehicles with 3.0L engine
Exhaust manifold heat shield retaining bolts – Ve- 11 8 –
hicles with 3.0L engine
Heated oxygen sensor 48 35 –
Catalytic monitor sensor 46 34 –
Catalytic converter support bracket retaining bolts 46 34 –
Catalytic converter to turbocharger nuts 46 34 –
Catalytic converter to front muffler pipe nuts 46 34 –
Catalytic converter to exhaust manifold nuts 46 34 –
Catalytic converter to exhaust manifold nuts – Ve- 25 18 –
hicles with 3.0L engine
Catalytic converter heat shield retaining bolts – 11 8 –
Vehicles with 3.0L engine
Catalytic converter to engine block nuts – Vehicles 23 17 –
with 3.0L engine
Turbocharger heatshield retaining bolts 8 – 71
Dual converter Y-pipe support bracket retaining 10 – 89
nut
Dual converter Y-pipe to rear catalytic converter 46 34 –
nuts
Dual converter Y-pipe to left-hand side catalytic 46 34 –
converter nuts
Dual converter Y-pipe to right-hand side catalytic 46 34 –
converter nuts
Right-hand wiring rail retaining nuts – Vehicles 6 – 53
with 3.0L engine

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309-00-3 Exhaust System 309-00-3

DESCRIPTION AND OPERATION

Exhaust System
DESCRIPTION AND OPERATION

Vehicles with 1.8L and 2.0L engine

Item Part Description

Item Part Description Number
Number
4 Muffler and tailpipe assem-
1 Exhaust flexible pipe bly
2 Catalytic converter 5 Hanger and insulator - se-
3 Heated oxygen sensor dan only

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309-00-4 Exhaust System 309-00-4

DESCRIPTION AND OPERATION

Vehicles with 2.5L engine

Item Part Description

Item Part Description Number
Number
3 Heated oxygen sensor
1 Dual converter Y-pipe
4 Muffler and tailpipe assem-
2 Catalytic converter bly

G37669 en 08/2002 2003.0 Mondeo

309-00-5 Exhaust System 309-00-5

DESCRIPTION AND OPERATION

Vehicles with Diesel engine

Item Part Description

Number
1 Catalytic converter
2 Exhaust flexible pipe
3 Muffler and tailpipe assem-
bly

G37669 en 08/2002 2003.0 Mondeo

309-00-6 Exhaust System 309-00-6

REMOVAL AND INSTALLATION

Dual Converter Y-Pipe (25 002 0)

REMOVAL AND INSTALLATION

4. Detach the dual converter Y-pipe from the

right-hand exhaust manifold flange.
Name Specification • Discard the nuts.

Lubricant ESE-M99B144-B
Anti-seize grease SAM-1C9107A

Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. CAUTION: Over bending of the exhaust
flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a 5. Detach the dual converter Y-pipe from the
support wrap or suitable splint. catalytic converter.
• Discard the gasket and nuts.

3. Detach the dual converter Y-pipe from the

left-hand exhaust manifold flange. 6. Remove the dual converter Y-pipe exhaust
• Discard the nuts. hanger insulator.

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309-00-7 Exhaust System 309-00-7

REMOVAL AND INSTALLATION (Continued)

7. Remove the dual converter Y-pipe.

Installation
1. CAUTION: Never use a jointing
compound forward of the catalytic
converter.
NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install new gaskets and nuts.
NOTE: Check the exhaust hanger insulator for
damage and fatigue. Install a new exhaust
hanger insulator as required, using a suitable
lubricant.
To install, reverse the removal procedure.

G37670 en 08/2002 2003.0 Mondeo

309-00-8 Exhaust System 309-00-8

REMOVAL AND INSTALLATION

Catalytic Converter — 1.8L/2.0L (25 250 0)

4. Detach the catalyst monitor sensor wiring
harness.
Name Specification
Anti-seize grease SAM-1C9107A

Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. CAUTION: Over bending of the exhaust
flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a
5. Remove the catalyst monitor sensor.
support wrap or suitable splint.

6. Detach the exhaust flexible pipe from the

3. Disconnect the catalyst monitor sensor
catalytic converter.
electrical connector.
• Discard the gasket and nuts.

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309-00-9 Exhaust System 309-00-9

REMOVAL AND INSTALLATION (Continued)

7. Remove the catalytic converter.

• Discard the gasket and nuts.

Installation
1. CAUTION: Never use jointing
compound forward of the catalytic
converter.
NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install new gaskets and nuts.
To install, reverse the removal procedure.

G37671 en 08/2002 2003.0 Mondeo

309-00-10 Exhaust System 309-00-10

REMOVAL AND INSTALLATION

Catalytic Converter — 2.5L (25 250 0)

4. Detach the catalyst monitor sensor wiring
harness.
Name Specification
Anti-seize grease SAM-1C9107A

Removal
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. CAUTION: Over bending of the flexible
pipe may cause damage resulting in
failure.
Support the flexible pipe with a support
5. Remove the catalyst monitor sensor.
wrap or suitable splint.

6. Detach the dual converter Y-pipe from the

3. Disconnect the catalyst monitor sensor
catalytic converter.
electrical connector.
• Discard the gasket and nuts.

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309-00-11 Exhaust System 309-00-11

REMOVAL AND INSTALLATION (Continued)

7. Detach the catalytic converter from the

front muffler pipe.
• Discard the gasket and nuts.

8. Remove the catalytic converter.

Installation
1. CAUTION: Never use a jointing
compound forward of the catalytic
converter.
NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install a new gasket and nuts.
To install, reverse the removal procedure.

G37672 en 08/2002 2003.0 Mondeo

309-00-12 Exhaust System 309-00-12

REMOVAL AND INSTALLATION

Exhaust Flexible Pipe (25 004 0)

4. Remove the exhaust flexible pipe.
• Discard the gasket and nuts.
Name Specification
Anti-seize grease SAM-1C9107-A

Removal
All vehicles
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. CAUTION: Over bending of the exhaust
flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a Vehicles with 1.8L or 2.0L engine
support wrap or suitable splint. 5. Detach the exhaust flexible pipe from the
catalytic converter.
• Discard the gasket and nuts.

Vehicles with diesel engine

3. Detach the exhaust flexible pipe from the
catalytic converter. 6. Remove the exhaust flexible pipe.
• Discard the gasket and nuts. • Discard the gasket and nuts.

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309-00-13 Exhaust System 309-00-13

REMOVAL AND INSTALLATION (Continued)

Vehicles with 3.0L engine Installation

7. Detach the exhaust flexible pipe from the
catalytic converter (left-hand shown). 1. CAUTION: Never use jointing
compound forward of the catalytic
converter.
NOTE: Coat the front muffler pipe and catalytic
converter studs with anti-seize grease.
NOTE: Install new exhaust flexible pipe gasket(s)
and nuts.
To install reverse the removal procedure.

8. Detach the exhaust flexible pipe from the

exhaust flexible pipe support bracket (if
equipped).

9. Remove the exhaust flexible pipe (left-

hand shown).
• Discard the gasket and nuts.

G37674 en 08/2002 2003.0 Mondeo

310-00-1 Fuel System - General Information 310-00-1

SECTION 310-00 Fuel System - General Information

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Fuel System — 1.8L/2.0L/2.5L/3.0L .................................................................................. 310-00-2

Inspection and Verification ............................................................................................... 310-00-2

GENERAL PROCEDURES

Fuel System Pressure Release .................................................................... (23 420 0) 310-00-3

Fuel Tank Draining ....................................................................................... (23 551 0) 310-00-4
Spring Lock Couplings.................................................................................. (23 004 0) 310-00-5
Quick Release Coupling .................................................................................................... 310-00-8

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310-00-2 Fuel System - General Information 310-00-2

DIAGNOSIS AND TESTING

Fuel System — 1.8L/2.0L/2.5L/3.0L

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Fuel level – Electrical
– Fuel leak(s) connector(s)
– Fuel line(s) – Wiring harness
– Fuel filter – Inertia fuel shutoff
(IFS) switch
– Fuel tank
– Fuel tank filler pipe
– Fuel filler cap
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 WDS to diagnose
the system.

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310-00-3 Fuel System - General Information 310-00-3

GENERAL PROCEDURES

Fuel System Pressure Release (23 420 0)

GENERAL PROCEDURES

Release
1. 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
vapors are always present and may
ignite. Failure to follow these
instructions may result in personal
injury.
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel
pressure must be released before
attempting any repairs. Failure to follow
this instruction may result in personal
injury.
Remove the fuel pump fuse.
2. Start the engine and allow to idle until the
engine stalls.
3. Crank the engine for approximately five
seconds to make sure the fuel injection
supply manifold pressure has been
released.
4. Install the fuel pump fuse.

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310-00-4 Fuel System - General Information 310-00-4

GENERAL PROCEDURES

Fuel Tank Draining (23 551 0)

Draining
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel
pressure must be relieved before
attempting any repairs. Failure to follow
these instructions may result in personal
injury.
1. Disconnect the battery ground cable.
2. Remove the fuel filler cap.
3. NOTE: To enable the hose to enter the fuel
tank it is necessary to cut a 40mm long taper
at the end.
Drain the fuel from the fuel tank using a
12.5mm nylon drain tube with the ap-
proved ford fuel drain tank.

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310-00-5 Fuel System - General Information 310-00-5

GENERAL PROCEDURES

Spring Lock Couplings (23 004 0)

WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
Special Tool(s) all times and always observe fuel
handling precautions. Failure to follow
Disconnect Tool, Spring Lock these instructions may result in personal
Coupling (3/8”yellow) injury.
310-D004 (23-039) 1. Release the fuel system pressure. For
additional information, refer to Fuel
System Pressure Release in this section.
2. Install the special tool to the fuel line.

Disconnect Tool, Spring Lock

Coupling (1/2”green)
310-D005 (23-040)

Disconnect Tool, Spring Lock

Coupling (5/8” black)
412-038 (34-003)

3. NOTE: Both sides of the spring lock coupling

Disconnect Tool, Fuel Line fuel line must be pushed together to enable
(5/16”) the special tool to release the spring lock
310-040 (23-041) coupling locking tangs.
Slide the special tool into the spring lock
coupling to release the locking tangs.

Disconnection
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel
pressure must be released before
attempting any repairs. Failure to follow
these instructions may result in personal
injury.

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310-00-6 Fuel System - General Information 310-00-6

GENERAL PROCEDURES (Continued)

4. Disconnect the fuel line from the spring 7. Close and push the fuel line spring lock
lock coupling. coupling tool into the open side of the
• Allow the fuel to drain into a suitable con- cage.
tainer.

8. Separate the fuel line spring lock coupling.

5. Remove the safety clips from the fuel line

spring lock couplings.

9. Remove the special tool.

6. Install the special tool onto the fuel line

spring lock coupling.

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310-00-7 Fuel System - General Information 310-00-7

GENERAL PROCEDURES (Continued)

Installation 2. NOTE: Lubricate the O-rings seals with clean

engine oil.
WARNING: Do not smoke or carry lighted
tobacco or open flame of any type when Insert the male fitting into the female end
working on or near any fuel related and push until the garter spring snaps
components. Highly flammable vapors over the flared end of the female fitting.
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
WARNING: The fuel system remains
pressurized for a long time after the
ignition is switched off. The fuel
pressure must be released before
attempting any repairs. Failure to follow
these instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel 3. Make sure the fuel line spring lock cou-
handling precautions. Failure to follow pling is engaged by pulling on the lines.
these instructions may result in personal
injury.
1. Inspect and clean both fuel line spring lock
coupling ends. Install new O-rings and gar-
ter springs if necessary.

4. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line spring lock
coupling and an audible click is heard.
Install the spring lock coupling to the fuel
line.

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310-00-8 Fuel System - General Information 310-00-8

GENERAL PROCEDURES

Quick Release Coupling

Disconnection 3. Disconnect the fuel line quick release

coupling.
WARNING: Do not carry lighted tobacco 1. Pull the fuel line quick release coupling
or open flame of any type when working locking tang.
on or near any fuel related components. 2. Push the clip through the fuel line quick
Highly flammable vapors are always release coupling to release the fuel line.
present and can ignite. Failure to follow
these instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
CAUTION: Fuel injection equipment is
manufactured to very precise tolerances
and fine clearances. It is therefore
essential that absolute cleanliness is
observed when working with these
components. Always install blanking 4. Disconnect the fuel line quick release
plugs to any open orifices or lines. coupling.
NOTE: Fuel supply line connectors are white or 1. Press the fuel line quick release coupling
are identified by a white band. Fuel return line locking tangs.
connectors are red or are identified by a red 2. Disconnect the fuel line quick release cou-
band. pling.
1. Release the fuel system pressure. For
additional information, refer to Fuel
System Pressure Release in this section.
2. Disconnect the fuel line quick release
coupling.
1. Press the fuel line quick release coupling
locking tangs.
2. Disconnect the fuel line quick release cou-
pling.

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310-00-9 Fuel System - General Information 310-00-9

GENERAL PROCEDURES (Continued)

5. Disconnect the fuel line quick release 8. Release the fuel line quick release
coupling. coupling.
• Press the fuel line quick release coupling • Press the fuel line quick release coupling
buttons and pull the fuel line to disconnect. locking release collar.

6. Release the fuel tank vent line quick 9. Disconnect the fuel line quick release cou-
release coupling. pling.
• Press the fuel tank vent line quick release
coupling locking release collar.

Connect
7. Disconnect the fuel tank vent line quick
release coupling. WARNING: Do not carry lighted tobacco
or open flame of any type when working
on or near any fuel related components.
Highly flammable vapors are always
present and can ignite. Failure to follow
these instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.

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310-00-10 Fuel System - General Information 310-00-10

GENERAL PROCEDURES (Continued)

CAUTION: Fuel injection equipment is 3. CAUTION: Make sure the fuel line
manufactured to very precise tolerances clicks into place when installing the
and fine clearances. It is therefore line. To make sure that the fuel line is
essential that absolute cleanliness is fully seated, pull on the line.
observed when working with these
Install the fuel line quick release coupling.
components. Always install blanking
plugs to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red
band.
1. CAUTION: After installation, to make
sure that the fuel line is fully seated,
pull on the line.
Install the fuel line quick release coupling.

4. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
coupling.
Install the fuel line quick release coupling.

2. CAUTION: After installation , to make

sure that the vent line is fully seated,
pull on the line.
Install the fuel tank vent line quick release
coupling.

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310-00-11 Fuel System - General Information 310-00-11

GENERAL PROCEDURES (Continued)

5. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
coupling before the locking tang is locked.
Install the fuel line quick release coupling.
1. Install the fuel line quick release coupling
locking tang.
2. Rotate the fuel line quick release coupling
locking tang into position.

6. NOTE: Make sure the collar on the fuel line is

inserted fully into the fuel line quick release
coupling before the locking tang is locked.
Install the fuel line quick release coupling.
1. Install the fuel line quick release coupling.
2. Press the fuel line quick release coupling
locking tang into position.

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310-01-1 Fuel Tank and Lines 310-01-1

SECTION 310-01 Fuel Tank and Lines

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 310-01-2

DESCRIPTION AND OPERATION

Fuel Tank and Lines .......................................................................................................... 310-01-3

DIAGNOSIS AND TESTING

Fuel Tank and Lines .......................................................................................................... 310-01-9

Inspection and Verification ............................................................................................... 310-01-9

REMOVAL AND INSTALLATION

Fuel Tank ..................................................................................................... (23 554 0) 310-01-10

Fuel Pump Module ....................................................................................... (23 534 0) 310-01-16
Fuel Level Sensor.............................................................................................................. 310-01-17
Fuel Tank Filler Pipe..................................................................................... (23 572 0) 310-01-18
Fuel Filter — 1.8L/2.0L/2.5L/3.0L ................................................................. (23 545 0) 310-01-21

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310-01-2 Fuel Tank and Lines 310-01-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Fuel tank support strap retaining bolts 25 18 -
Fuel filter retaining bolt - All except vehicles with 9 - 80
diesel engine
Fuel pump retaining bolts - Vehicles with 115 PS 9 - 80
diesel engine
Fuel pump module - All except vehicles with diesel 85 63 -
engine
Fuel level sensor - Vehicles with diesel engine 85 63 -
Rear crossmember retaining bolts 120 89 -
Rear stabilizer bar connecting link retaining nuts 48 35 -

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310-01-3 Fuel Tank and Lines 310-01-3

DESCRIPTION AND OPERATION

Fuel Tank and Lines

DESCRIPTION AND OPERATION

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310-01-4 Fuel Tank and Lines 310-01-4

DESCRIPTION AND OPERATION (Continued)

Fuel Tank and Lines

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310-01-5 Fuel Tank and Lines 310-01-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
1 - Fuel pump module/fuel level 9 - Fuel tank heat shield retain-
sensor ing clips
2 - Fuel tank 10 - Fuel tank support straps
3 - Lower fuel tank filler pipe re- 11 - Fuel tank support strap re-
taining bolts taining bolts
4 - Upper Fuel tank filler pipe 12 - Fuel tank support strap insu-
retaining bolt lator
5 - Fuel tank filler pipe 13 - Fuel filter - All except vehi-
cles with diesel engine
6 - Fuel tank filler pipe breather
hose 14 - Fuel pump - Vehicles with
115 PS diesel engine
7 - Heat shield - Wagon
8 - Fuel tank heat shield

Fuel Pump - Vehicles with 115 PS Diesel Engine

Item Part Description

Item Part Description Number
Number
2 - Fuel pump to fuel tank return
1 - Fuel pump line

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310-01-6 Fuel Tank and Lines 310-01-6

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
3 - Fuel tank to fuel pump sup- 4 - Fuel pump to fuel filter sup-
ply line ply line

Fuel Cooler - Vehicles with 115 PS Diesel Engine

Item Part Description

Number
1 - Cooling fins

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310-01-7 Fuel Tank and Lines 310-01-7

DESCRIPTION AND OPERATION

Fuel Filter - Vehicles with 2.0L Diesel Engine

Item Part Description

Item Part Description Number
Number
3 - Fuel filter to fuel tank fuel re-
1 - Fuel filter to fuel injection turn line
pump fuel supply line
4 - Fuel injection pump to fuel
2 - Fuel tank to fuel filter fuel filter fuel return line
supply line
5 - Fuel return line regulating
valve

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310-01-8 Fuel Tank and Lines 310-01-8

DESCRIPTION AND OPERATION

Vehicles with 2.0L Diesel Engine with Common Rail Fuel Injection

Item Part Description

Item Part Description Number
Number
4 - Fuel pump to fuel filter fuel
1 - Fuel filter return line
2 - Water drain plug 5 - Fuel filter to fuel pump fuel
3 - Fuel tank to fuel filter fuel supply line
supply line If carrying out a fuel filter water drain procedure
the fuel filter must be removed.

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310-01-9 Fuel Tank and Lines 310-01-9

DIAGNOSIS AND TESTING

Fuel Tank and Lines

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Fuel leak(s)– Fuse(s)
– Fuel line(s)– Wiring harness
– Fuel filler cap
– Electrical
– Fuel filter connector(s)
– Fuel tank – Inertia fuel shutoff
– (IFS) switch
Fuel tank filler pipe
– Fuel pump module -
– Fuel tank roll–over
All except vehicles
valve(s)
with diesel engine
– Fuel level sensor -
Vehicles with 2.0L
diesel engine
– Fuel pump - Vehi-
cles with 2.0L diesel
engine
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

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310-01-10 Fuel Tank and Lines 310-01-10

REMOVAL AND INSTALLATION

Fuel Tank (23 554 0)

REMOVAL AND INSTALLATION

Wagon
4. Detach the exhaust system from the front
exhaust hanger insulator.
Special Tool(s)
Wrench, Sender Unit, Fuel
Tank
310-069 (23-055)

General Equipment
Transmission jack

Name Specification
Petroleum Jelly WSM-M1C226-A
5. Detach the exhaust system from the mid-
dle exhaust hanger insulator.
Removal
All vehicles
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow All vehicles
these instructions may result in personal 6. Detach the exhaust system from the rear
injury. exhaust hanger insulator.
1. Release the fuel system pressure. For
additional information, refer to Section
310-00.
2. Drain the fuel tank. For additional
information, refer to Section 310-00.
3. Raise and support the vehicle. For
additional information, refer to Section
100-02.

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310-01-11 Fuel Tank and Lines 310-01-11

REMOVAL AND INSTALLATION (Continued)

7. Remove the exhaust system heat shield. All vehicles

11. Disconnect the fuel tank filler pipe from
the fuel tank.

All except vehicles with diesel engine

8. Disconnect the fuel tank to fuel filter fuel
supply line and the fuel filter to fuel injec- 12. CAUTION: When removing the fuel
tion supply manifold fuel supply line from tank vent pipe, do not use any sharp
the fuel filter. For additional information, edged tools to lever off the pipe.
refer to Section 310-00. Failure to follow this instruction may
cause damage to the vent pipe.
Disconnect the fuel tank vent pipe from
the fuel tank.

9. Remove the fuel filter.

Vehicles with xenon headlamps

13. Remove the headlamp leveling sensor.
For additional information, refer to
Section 417-01.

Vehicles with 115 PS diesel engine

10. Remove the fuel pump. For additional
information, refer to Fuel Pump in this
section.

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310-01-12 Fuel Tank and Lines 310-01-12

REMOVAL AND INSTALLATION (Continued)

All Vehicles 17. Detach the fuel tank support straps.
14. Detach the stabilizer bar connecting link
from the stabilizer bar on both sides.

18. Remove the fuel tank support straps.

1. Rotate the fuel tank support straps.
15. Remove the stabilizer bar bush retaining
2. Pull the fuel tank support straps down to
clamps from both sides and remove the remove.
stabilizer bar.

19. Disconnect the fuel return line. For addi-

16. CAUTION: Use a suitable packing tional information, refer to Section 310-
material to prevent damage to the 00.
underside of the fuel tank and heat
shield.
Using a suitabletransmission jack, sup-
port the fuel tank.

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310-01-13 Fuel Tank and Lines 310-01-13

REMOVAL AND INSTALLATION (Continued)

All except vehicles with diesel engine 23. Disconnect the fuel supply and fuel re-
20. Disconnect the evaporative emission turn lines from the fuel pump module. For
canister purge valve hose from the fuel additional information, refer to Section
tank. 310-00.

All vehicles Vehicles with diesel engine

24. Disconnect the fuel level sensor electri-
21. CAUTION: When lowering the fuel cal connector.
tank, make sure that excessive strain
is not placed on the fuel lines and
electrical connectors.
Partially lower the fuel tank.
All except vehicles with diesel engine
22. Disconnect the fuel pump module electri-
cal connector.

25. Disconnect the fuel supply and fuel re-

turn lines from the fuel level sensor. For
additional information, refer to Section
310-00.

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310-01-14 Fuel Tank and Lines 310-01-14

REMOVAL AND INSTALLATION (Continued)

All vehicles Vehicles with diesel engine
26. Remove the fuel tank. 29. Using the special tool, remove the fuel
All except vehicles with diesel engine level sensor locking ring.
27. Using the special tool, remove the fuel
pump module locking ring.

30. CAUTION: Make sure that the float or

arm are not damaged while removing
28. CAUTION: Make sure that the float or or installing the fuel level sensor.
arm are not damaged while removing Remove the fuel level sensor.
or installing the fuel pump module. 1. Rotate the sensor counterclockwise.
Remove the fuel pump module. 2. Lift the sensor from the fuel tank.
1. Rotate the module counterclockwise. • Discard the O-ring seal.
2. Lift the module from the fuel tank.
• Discard the O-ring seal.

Installation
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 vapors
are always present and may ignite.
Failure to follow these instructions may
result in personal injury.

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310-01-15 Fuel Tank and Lines 310-01-15

REMOVAL AND INSTALLATION (Continued)

WARNING: This procedure involves fuel

handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
CAUTION: Lubricate the fuel tank filler
pipe lower end to aid installation and to
make sure that the fuel tank filler pipe
seal in the fuel tank is not damaged
during installation of the fuel tank filler
pipe.
NOTE: Inspect the fuel tank filler pipe seal inside
the fuel tank for damage. Install a new fuel tank if
the seal is damaged.
NOTE: Install a new O-ring seal and make sure it
is seated correctly on the fuel tank.
NOTE: Make sure that the arrows on the fuel
tank and fuel pump module or fuel level sensor
are aligned correctly.
NOTE: Make sure that the insulator pads are
fitted to the fuel tank support straps.
1. To install, reverse the removal procedure.
• Using suitable petroleum jelly lubricate the
fuel tank filler pipe before inserting it into
the fuel tank.

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310-01-16 Fuel Tank and Lines 310-01-16

REMOVAL AND INSTALLATION

Fuel Pump Module (23 534 0)

Removal
1. Remove the fuel pump module. For
additional information, refer to Fuel Tank
in this section.

Installation
1. To install, reverse the removal procedure.

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310-01-17 Fuel Tank and Lines 310-01-17

REMOVAL AND INSTALLATION

Fuel Level Sensor

Removal
1. Remove the fuel level sensor. For
additional information, refer to Fuel Tank
in this section.

Installation
1. To install, reverse the removal procedure.

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310-01-18 Fuel Tank and Lines 310-01-18

REMOVAL AND INSTALLATION

Fuel Tank Filler Pipe (23 572 0)

All vehicles
4. Remove the fender splash shield.
Special Tool(s)
Alignment pins, Subframe
205-136 (15-197A)

General Equipment
Transmission jack

Name Specification
Petroleum Jelly WSM-M1C226-A 5. Remove the fuel tank filler pipe upper
retaining bolt.
• Detach the ground wire from the fuel tank
Removal filler pipe upper retaining bolt.

All vehicles
1. 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
ignite. Failure to follow these
instructions may result in personal
injury.
Remove the right-hand rear road wheel.
For additional information, refer to Section
204-04.
4-door and 5-door
4-door and 5-door
2. Remove the fuel tank. For additional
6. Using a suitable transmission jack and
information, refer to Fuel Tank in this
suitable wooden blocks, support the rear
section.
crossmember.
Wagon
3. Drain the fuel tank. For additional
information, refer to Section 310-00.

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310-01-19 Fuel Tank and Lines 310-01-19

REMOVAL AND INSTALLATION (Continued)

7. Detach the rear crossmember (two bolts Installation

each side).
All vehicles
1. 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
ignite. Failure to follow these
instructions may result in personal
injury.
NOTE: Inspect the fuel tank filler pipe seal inside
the fuel tank for damage. Install a new fuel tank if
the seal is damaged.
Install the fuel tank filler pipe and install
the fuel tank filler pipe retaining bolts.
8. CAUTION: Do not place excessive
strain on the brake hoses.
Partially lower the rear crossmember.
Wagon
9. Disconnect the fuel tank filler pipe from
the fuel tank.

Wagon
2. CAUTION: Lubricate the fuel tank filler
pipe bottom end to aid installation and
make sure that the fuel tank filler pipe
seal in the fuel tank is not damaged
during installation of the fuel tank
All vehicles filler pipe.
10. Remove the fuel tank filler pipe retaining
bolts and remove the fuel tank filler pipe. Using a suitable petroleum jelly lubri-
cate the fuel tank filler pipe before insert-
ing it into the fuel tank.

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310-01-20 Fuel Tank and Lines 310-01-20

REMOVAL AND INSTALLATION (Continued)

All vehicles
4-door and 5-door
3. Raise the rear crossmember. 6. NOTE: Make sure that the ground wire is
attached when installing the fuel tank filler pipe
4. Using the special tool, align the
upper retaining bolt.
crossmember.
1. Insert the alignment pins through the Install the fuel tank filler pipe upper retain-
crossmember alignment holes. ing bolt.
2. Slide the locking plates into the groove and
tighten the alignment pin sleeve.

7. Install the fender splash shield.

5. NOTE: Final tightening of the rear suspension

components should be carried out when the
vehicle weight is on the road wheels.
Install the rear crossmember bolts.
• Remove the transmission jack.

8. Install the right-hand rear road wheel.

For additional information, refer to Section
204-04.
4-door and 5-door
9. Install the fuel tank. For additional
information, refer to Fuel Tank in this
section.

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310-01-21 Fuel Tank and Lines 310-01-21

REMOVAL AND INSTALLATION

Fuel Filter — 1.8L/2.0L/2.5L/3.0L (23 545 0)

Removal 4. Disconnect the fuel tank to fuel filter fuel

supply line and the fuel filter to fuel injec-
1. WARNING: Do not smoke or carry
tion supply manifold fuel supply line from
lighted tobacco or open flame of any
the fuel filter. For additional information,
type when working on or near any fuel
refer to Section 310-00.
related components. Highly flammable
mixtures are always present and can
ignite. Failure to follow these
instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
Release the fuel system pressure. For
additional information, refer to Section
310-00.
2. Raise and support the vehicle. For 5. Remove the fuel filter from the fuel filter
additional information, refer to Section retaining bracket.
100-02. • Loosen the fuel filter retaining bracket bolt.
3. Remove the fuel filter bracket retaining
bolts.

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310-01-22 Fuel Tank and Lines 310-01-22

REMOVAL AND INSTALLATION (Continued)

Installation 3. Connect the fuel tank to fuel filter fuel
supply line and the fuel filter to fuel injec-
1. WARNING: Do not smoke or carry tion supply manifold fuel supply line to the
lighted tobacco or open flame of any fuel filter. For additional information, refer
type when working on or near any fuel to Section 310-00.
related components. Highly flammable
mixtures are always present and can
ignite. Failure to follow these
instructions may result in personal
injury.
WARNING: This procedure involves fuel
handling. Be prepared for fuel spillage at
all times and always observe fuel
handling precautions. Failure to follow
these instructions may result in personal
injury.
NOTE: Make sure the fuel filter is fully installed
into the fuel filter retaining bracket. Observe the
direction of flow arrows on the fuel filter and the
fuel filter bracket. 4. Install the fuel filter bracket retaining bolts.
Install the fuel filter to the fuel filter
bracket.

5. Lower the vehicle.

2. Tighten the fuel filter retaining bracket

bolt.

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310-02-1 Acceleration Control 310-02-1

SECTION 310-02 Acceleration Control

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Acceleration Control .......................................................................................................... 310-02-2

Inspection and Verification ............................................................................................... 310-02-2
Symptom Chart ................................................................................................................ 310-02-2

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310-02-2 Acceleration Control — 1.8L/2.0L/2.5L/3.0L 310-02-2

DIAGNOSIS AND TESTING

Acceleration Control
DIAGNOSIS AND TESTING

Mechanical Electrical
– Accelerator pedal • Fuse(s)
Inspection and Verification
– Linkage • Relay(s)
1. Verify the customer concern. – Accelerator cable • Wiring harness
2. Visually inspect for obvious signs of • Electrical
mechanical or electrical damage. connector(s)
• Powertrain control
Visual Inspection Chart
module (PCM)
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 cause is not visually evident, verify the
symptom and refer to Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Accelerator pedal is hard to de- • Damaged accelerator cable. • INSTALL a new accelerator ca-
press or has a rough/raspy or ble.
sticky feel
• Accelerator cable incorrectly • CHECK the accelerator cable
installed. for the correct installation.
• Worn or damaged throttle body. • INSTALL a new throttle body.
REFER to Section 303-04A /
303-04B.
• Accelerator pedal does not re- • Weak or broken throttle body • INSTALL a new throttle body.
turn freely return spring. REFER to Section 303-04A /
303-04B.
• Worn or damaged throttle body. • INSTALL a new throttle body.
REFER to Section 303-04A /
303-04B.
• High engine idle speed • Damaged accelerator cable. • INSTALL a new accelerator ca-
ble.
• Accelerator cable incorrectly • CHECK the accelerator cable
installed. for the correct installation.

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310-03-1 Speed Control 310-03-1

SECTION 310-03 Speed Control

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 310-03-2

DESCRIPTION AND OPERATION

Speed Control ................................................................................................................... 310-03-3

DIAGNOSIS AND TESTING

Speed Control ................................................................................................................... 310-03-6

Inspection and Verification ............................................................................................... 310-03-6
Symptom Chart ................................................................................................................ 310-03-6
Pinpoint Test .................................................................................................................... 310-03-7
Component Tests - Speed Control Switch ........................................................................ 310-03-17

GENERAL PROCEDURES

Speed Control Deactivator Switch Adjustment.............................................. (33 504 0) 310-03-19

REMOVAL AND INSTALLATION

Speed Control Actuator ................................................................................ (33 678 0) 310-03-20

Speed Control Switch ................................................................................... (33 500 0) 310-03-25

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310-03-2 Speed Control 310-03-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Speed control actuator retaining nuts 9 - 80
Speed control actuator retaining screw 6 - 53
Speed control switch retaining bolts 5 - 44

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310-03-3 Speed Control 310-03-3

DESCRIPTION AND OPERATION

Speed Control
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 - Speed control set/accelerate
1 - Speed control status indica- and tap up switch
tor
4 - Speed control coast and tap
2 - Speed control resume switch down switch

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310-03-4 Speed Control 310-03-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description
Number Number
5 - Speed control deactivator 7 - Speed control de-activate
switch switch
6 - Speed control deactivator 8 - Speed control activate
switches switch

Item Part Description

Number
1 - Speed control actuator cable

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310-03-5 Speed Control 310-03-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
2 - Speed control actuator

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310-03-6 Speed Control 310-03-6

DIAGNOSIS AND TESTING

Speed Control
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 310-03 for 3. If an obvious cause for an observed or
schematic and connector information. reported concern is found, correct the cause
(if possible) before proceeding to the next
step.
Inspection and Verification
4. If the concern is not visually evident, verify
1. Verify the customer concern. the symptom and refer to WDS to diagnose
2. Visually inspect for obvious signs of electrical the fault, vehicles with diesel engine.
damage. 5. If the concern is not visually evident verify the
symptom and refer to the Symptom chart, all
Visual Inspection Chart except vehicles with diesel engine.
Mechanical Electrical
– Speed control ac- – Fuse(s)
tuator cable. – Wiring harness
– Electrical
connector(s)
– Speed control
switch(es)
– Speed control
actuator
– Powertrain control
module (PCM)
– Brake pedal position
(BPP) switch
– Clutch pedal posi-
tion (CPP) switch
Symptom Chart

Condition Possible Sources Action

• The speed control is inoperative • Fuse(s) • GO to Pinpoint Test A .
• Circuit(s).
• Speed control actuator.
• Steering wheel/speed control
switch.
• PCM.
• BPP switch.
• CPP switch.
• The speed control does not dis- • Circuit(s). • GO to Pinpoint Test B .
engage when the brakes are • BBP switch.
applied. • Speed control actuator.
• The speed control does not dis- • Circuit(s). • GO to Pinpoint Test C .
engage when the clutch is ap- • CPP switch.
plied. • Speed control actuator.
• The speed control switch does • Steering wheel/speed control • CARRY OUT the speed control
not operate correctly switch. switch component test in this
section.

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310-03-7 Speed Control 310-03-7

DIAGNOSIS AND TESTING

NOTE: Use a digital multimeter for all electrical

measurements.
Pinpoint Test
PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK CIRCUIT 15-PG12 (GN/WH) FOR POWER
1 Disconnect Speed control actuator C175.
2 Key in ON position.
3 Measure the voltage between the speed con-
trol actuator C175 pin 7, circuit 15-PG12
(GN/WH), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A2.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A2: CHECK CIRCUIT 31-PG12 (BK) TO GROUND
1 Key in OFF position.
2 Measure the resistance between the speed
control actuator C175 pin 10, circuit 31-PG12
(BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A3.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A3: CHECK CIRCUIT 8-PG13 (WH) FOR POWER
1 Key in ON position.
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310-03-8 Speed Control 310-03-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the speed con-
trol actuator C175 pin 5, circuit 8-PG13 (WH),
harness side and ground. When the speed
control switch is in the ON position.

• Is the voltage greater than 10 volts?

→ Yes
GO to A8.
→ No
GO to A4.
A4: CHECK CIRCUIT 15-PG13 (GN/YE) FOR POWER

WARNING: To deactivate the air bag module, refer to the procedure in Section 501-20B for
the correct air bag module deactivation procedure. Failure to follow this instruction may
result in personal injury.
1 Remove the driver air bag module, REFER to
Section 501-20A / 501-20B.
2 Disconnect Clock spring C413.
3 Connect the battery ground cable.
4 Key in ON position.
5 Measure the voltage between the clock spring
C413 pin 7, circuit 15-PG13 (GN/YE), harness
side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A5.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A5: CHECK CIRCUIT 8-PG13 (WH) FOR OPEN
1 Key in OFF position.

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310-03-9 Speed Control 310-03-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the clock
spring C413 pin 5 circuit 8-PG13 (WH), har-
ness side and the speed control actuator C175
pin 5 circuit 8-PG13 (WH), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to A6.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A6: CHECK THE CLOCK SPRING FOR OPEN
1 Disconnect Speed Control Switch.
2 Measure the resistance between the clock
spring pin 5, component side and the clock
spring to speed control switch connector.

• Is the resistance less than 1 ohms?

→ Yes
GO to A7.
→ No
INSTALL a new clock spring, REFER to
Section 501-20A / 501-20B. TEST the sys-
tem for normal operation.

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310-03-10 Speed Control 310-03-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A7: CHECK THE CLOCK SPRING FOR OPEN
1 Measure the resistance between the clock
spring pin 7, component side and the clock
spring to speed control switch connector.

• Is the resistance less than 1 ohms?

→ Yes
INSTALL a new speed control switch.
REFER to Speed Control Switch in this sec-
tion. TEST the system for normal operation.
→ No
INSTALL a new clock spring, REFER to
Section 501-20A / 501-20B. TEST the sys-
tem for normal operation.
A8: CHECK CIRCUIT 15S-PG16 (GN/YE) FOR POWER
1 Measure the voltage between the speed con-
trol actuator C175 pin 9, circuit 15S-PG16
(GN/YE), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A11.
→ No
GO to A9.
A9: CHECK CIRCUIT 15-PG6 (GN/YE) FOR POWER
1 Disconnect BPP switch C406.

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310-03-11 Speed Control 310-03-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the BPP switch
C406 pin 2, circuit 15-PG6 (GN/YE), harness
side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A10.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A10: CHECK CIRCUIT 15S-PG16 (GN/YE) FOR OPEN
1 Key in OFF position.
2 Measure the resistance between the speed
control module C175 pin 9, circuit 15S-PG16
(GN/YE), harness side and the BPP switch
C406 pin 1, circuit 15S-PG16 (GN/YE), har-
ness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new BPP switch. TEST the sys-
tem for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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310-03-12 Speed Control 310-03-12

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A11: CHECK CIRCUIT 15S-PG17 (GN/BU) TO GROUND
1 Measure the resistance between the speed
control actuator C175 pin 4, circuit 15S-PG17
(GN/BU), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A14.
→ No
IF the stop lamps operate correctly, GO to
A12. IF the stoplamps do not operate cor-
rectly. REFER to Section 417-01.
A12: CHECK CIRCUIT 15S-PG7 (GN/BU) TO GROUND
1 Disconnect CPP switch C414.
2 Measure the resistance between the CPP
switch C414 pin 3, circuit 15S-PG7 (GN/BU),
harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A13.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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310-03-13 Speed Control 310-03-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A13: CHECK CIRCUIT 15S-PG17 (GN/BU) FOR OPEN
1 Measure the resistance between the CPP
switch C414 pin 1, circuit 15S-PG17 (GN/BU)
harness side and the speed control actuator
C175 pin 4, circuit 15S-PG17 (GN/BU), har-
ness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new CPP switch. TEST the sys-
tem for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A14: CHECK THE VEHICLE SPEED SENSOR (VSS) FOR CORRECT OPERATION
1 Check the trip computer and speedometer for
correct operation.
• Is the instrument cluster working correctly.
→ Yes
GO to A15.
→ No
REFER to Section 413-01.
A15: CHECK CIRCUIT 8-PG18 (WH/BU) FOR OPEN
1 Disconnect PCM C100.
2 Measure the resistance between the PCM
C100 pin 28, circuit 8-GB8 (WH/BU), harness
side and the speed control module C175 pin 3,
circuit 8-PG18 (WH/BU), harness side.

• Is the resistance less than 5 ohms?

→ Yes

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310-03-14 Speed Control 310-03-14

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. TEST the system for normal opera-
tion.
→ No
REPAIR the circuit(s). TEST the system for
normal operation.
PINPOINT TEST B: THE SPEED CONTROL DOES NOT DISENGAGE WHEN THE BRAKES ARE
APPLIED.
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK CIRCUIT 15S-PG16 (GN/YE) FOR POWER
1 Disconnect Speed control module C175.
2 Key in ON position.
3 Measure the voltage between the speed con-
trol actuator C175 pin 9, circuit 15S-PG16
(GN/YE), harness side and ground.

• Is the voltage greater than 10 volts when the

brakes are applied?
→ Yes
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. TEST the system for normal opera-
tion.
→ No
GO to B2
B2: CHECK CIRCUIT 15-PG6 (GN/YE) FOR POWER
1 Disconnect BPP Switch C406.

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310-03-15 Speed Control 310-03-15

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the BPP switch
C406 pin 2, circuit 15-PG6 (GN/YE), harness
side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to B3.
→ No
REPAIR the circuit. TEST the system for
normal operation.
B3: CHECK CIRCUIT 15S-PG16 (GN/YE) FOR OPEN
1 Key in OFF position.
2 Measure the resistance between the BPP
switch C406 pin 1, circuit 15S-PG16 (GN/YE),
harness side and the speed control actuator
C175 pin 9, circuit 15S-PG16 (GN/YE), har-
ness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a BPP switch. TEST the system
for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
PINPOINT TEST C: THE SPEED CONTROL DOES NOT DISENGAGE WHEN THE CLUTCH IS
APPLIED.
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK CIRCUIT 15S-PG17 (GN/BU) FOR OPEN
1 Key in OFF position.
2 Disconnect Speed Control Actuator C175.

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310-03-16 Speed Control 310-03-16

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the speed
control module C175 pin 4, circuit 15S-PG17
(GN/BU), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new speed control actuator.
REFER to Speed Control Actuator in this
section. TEST the system for normal opera-
tion.
→ No
IF the stop lamps operate correctly, GO to
C2. IF the stoplamps do not operate cor-
rectly. REFER to Section 417-01.
C2: CHECK CIRCUIT 15S-PG7 (GN/BU) FOR OPEN
1 Disconnect CPP switch C414.
2 Measure the resistance between the CPP
switch C414 pin 3, circuit 15S-PG7 (GN/BU),
harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to C3.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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310-03-17 Speed Control 310-03-17

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C3: CHECK CIRCUIT 15S-PG17 (GN/BU) FOR OPEN
1 Measure the resistance between the CPP
switch C414 pin 1, circuit 15S-PG17 (GN/BU)
harness side and the speed control actuator
C175 pin 4, circuit 15S-PG17 (GN/BU), har-
ness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new CPP switch. TEST the sys-
tem for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
Measure resistance between pin 1 and pin 3.
Component Tests - Speed Control Switch Is the resistance less than 830 ohms?
If yes, continue with Test 2.
WARNING: To deactivate the air bag
module, refer to the procedure in Section If no, INSTALL a new speed control switch.
501-20B for the correct air bag module REFER to Speed Control Switch in this section.
deactivation procedure. Failure to follow TEST the system for normal operation.
this instruction may result in personal
injury.
Test 2
Remove the driver air bag. REFER to Section
501-20A / 501-20B.

Test 1

Hold the speed control switch in the OFF

position.
Measure resistance between pin 2 and pin 3.
Is the resistance 0 ohms?
Hold the speed control switch in the ON position.

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310-03-18 Speed Control 310-03-18

DIAGNOSIS AND TESTING (Continued)

If yes, continue with Test 3. If yes, continue with Test 5.
If no, INSTALL a new speed control switch. If no, INSTALL a new speed control switch.
REFER to Speed Control Switch in this section. REFER to Speed Control Switch in this section.
TEST the system for normal operation. TEST the system for normal operation.

Test 3 Test 5

Hold the speed control switch in the SET Hold the speed control switch in the
position. DECELERATE position.
Measure resistance between pin 2 and pin 3. Measure resistance between pin 2 and pin 3.
Is the resistance less than 690 ohms? Is the resistance less than 120 ohms?
If yes, continue with Test 4. If yes, INSTALL a new speed control module.
TEST the system for normal operation.
If no, INSTALL a new speed control switch.
REFER to Speed Control Switch in this section. If no, INSTALL a new speed control switch.
TEST the system for normal operation. REFER to Speed Control Switch in this section.
TEST the system for normal operation.
Test 4

Hold the speed control switch in the RESUME

position.
Measure resistance between pin 2 and pin 3.
Is the resistance less than 2250 ohms?

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310-03-19 Speed Control 310-03-19

GENERAL PROCEDURES

Speed Control Deactivator Switch Adjustment (33 504 0)

GENERAL PROCEDURES

1. Adjust the switch.

1. Pull the switch plunger out to its full extent.
2. Fully depress the pedal.
3. Install the switch.
4. Slowly release the pedal.

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310-03-20 Speed Control 310-03-20

REMOVAL AND INSTALLATION

Speed Control Actuator (33 678 0)

REMOVAL AND INSTALLATION

Removal 4. Detach the strut and spring assembly top

mount from the strut and spring assembly
1. Detach the positive crankcase ventilation
top mount brace.
(PCV) hose and the vacuum hose from the
engine upper cover.

5. Detach the strut and spring assembly top

mount brace from the cowl.
2. Remove the engine upper cover.

6. Remove the strut and spring assembly top

3. Remove the strut and spring assembly top
mount brace.
mount brace cover.

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310-03-21 Speed Control 310-03-21

REMOVAL AND INSTALLATION (Continued)

7. Detach the speed control cable from the 9. Remove the speed control actuator retain-
throttle body. ing bolt.
1. Disconnect the speed control cable from
the throttle linkage.
2. Unclip the speed control cable.

10. Detach the speed control actuator from

the retaining bracket.

8. Detach the speed control cable.

11. Disconnect the speed control actuator

electrical connector.

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310-03-22 Speed Control 310-03-22

REMOVAL AND INSTALLATION (Continued)

12. Remove the speed control actuator. Installation
1. Install the speed control cable onto the
speed control actuator.

13. Detach the speed control cable from the

actuator.
1. Press and hold the locking clip.
2. Pull the speed control cable to make sure
2. Rotate the cap counterclockwise.
that there is no free play at the speed con-
trol actuator.

14. Remove the speed control cable from the

speed control actuator.
3. Install the speed control cable cap.
1. Gently release the cable locking spring.
1. Install the speed control cable cap into the
2. Push the cable end out of the speed con- speed control actuator.
trol actuator pulley slot.
2. Rotate the speed control cable cap clock-
wise 90 degrees.

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310-03-23 Speed Control 310-03-23

REMOVAL AND INSTALLATION (Continued)

4. Install the speed control actuator. 7. Attach the speed control cable.

5. Connect the speed control actuator elec-

trical connector.

8. Attach the speed control cable to the

throttle body.
1. Attach the speed control cable.
6. Install the speed control actuator retaining
bolt. 2. Connect the speed control cable to the
throttle linkage.

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310-03-24 Speed Control 310-03-24

REMOVAL AND INSTALLATION (Continued)

9. Install the strut and spring assembly top 12. Install the strut and spring assembly top
mount brace. mount brace cover.

10. Install the strut and spring assembly top 13. Install the engine upper cover.
mount brace retaining bolts.

14. Attach the positive crankcase ventilation

11. Install the strut and spring assembly re- (PCV) hose and the vacuum hose to the
taining nuts. engine upper cover.

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310-03-25 Speed Control 310-03-25

REMOVAL AND INSTALLATION

Speed Control Switch (33 500 0)

Removal
1. Remove the driver air bag module. For
additional information, refer to Section
501-20A / 501-20B.
2. Detach the vehicle speed control wiring
harness from the horn switch.

3. Remove the speed control switches from

the driver air bag module.

Installation
1. To install, reverse the removal procedure.

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 Group

SECTION TITLE PAGE

Climate Control System

Climate Control System - General Information ...................................................................... 412-00-1
Air Distribution and Filtering................................................................................................... 412-01-1
Heating and Ventilation ......................................................................................................... 412-02A-1
Auxiliary Heating ................................................................................................................... 412-02B-1
Air Conditioning ..................................................................................................................... 412-03-1
Control Components ............................................................................................................. 412-04-1
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination ............................................................................. 413-00-1
Instrument Cluster ................................................................................................................. 413-01-1
Horn ...................................................................................................................................... 413-06-1
Clock ..................................................................................................................................... 413-07-1
Information and Message Center .......................................................................................... 413-08-1
Warning Devices ................................................................................................................... 413-09-1
Battery and Charging System
Charging System - General Information ................................................................................ 414-00-1
Battery, Mounting and Cables ............................................................................................... 414-01-1
Generator and Regulator....................................................................................................... 414-02-1
Entertainment Systems
Entertainment System - General Information......................................................................... 415-00-1
Audio Unit.............................................................................................................................. 415-01-1
Antenna................................................................................................................................. 415-02-1
Speakers ............................................................................................................................... 415-03-1
Lighting
Exterior Lighting .................................................................................................................... 417-01-1
Interior Lighting...................................................................................................................... 417-02-1
Electrical Distribution
Module Communications Network ......................................................................................... 418-00-1
Module Configuration ............................................................................................................ 418-01-1
Electronic Feature Group
Anti-Theft - Passive ............................................................................................................... 419-01-1
Cellular Phone....................................................................................................................... 419-08-1
Multifunction Electronic Modules ........................................................................................... 419-10-1

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412-00-1 Climate Control System - General Information 412-00-1

SECTION 412-00 Climate Control System - General

Information
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 412-00-2

DIAGNOSIS AND TESTING

Climate Control System ..................................................................................................... 412-00-3

Inspection and Verification ............................................................................................... 412-00-3
Fault Memory Interrogation without WDS (Vehicles with EATC System only)................... 412-00-3
Trouble Code Table (Vehicles with EATC System only) ................................................... 412-00-3
Symptom Chart ................................................................................................................ 412-00-4
Pinpoint Tests .................................................................................................................. 412-00-6
Component Tests ............................................................................................................. 412-00-67
Testing the Refrigerant Circuit .......................................................................................... 412-00-67

GENERAL PROCEDURES

Spring Lock Coupling ........................................................................................................ 412-00-71

Air Conditioning (A/C) Clutch Air Gap Adjustment ........................................ (34 628 6) 412-00-73
Air Conditioning (A/C) System Recovery, Evacuation and Charging............. (34 620 2) 412-00-74
Refrigerant Oil Adding .................................................................................. (34 621 1) 412-00-76
Electronic Leak Detection ............................................................................. (34 620 7) 412-00-77
Flourescent Dye Leak Detection........................................................................................ 412-00-78
Vacuum Leak Detection................................................................................ (34 620 3) 412-00-79
Contaminated Refrigerant Handling.............................................................. (34 620 9) 412-00-80

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412-00-2 Climate Control System - General Information 412-00-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
R134a refrigerant WSH-M17B19-A
Refrigerant oil WSH-M1C231-B

Refrigerant Capacities (when charging)

Grams
Air conditioning (A/C) system 820 ± 17

Refrigerant Oil Capacities

Milliliters
Air conditioning (A/C) system 200

Addition of Air Conditioning Refrigerant Oil (when components are renewed)

Milliliters
Air conditioning (A/C) compressor, if the quantity of refrigerant Add 90.
oil taken from the A/C compressor is less than 90 ml.
Air conditioning (A/C) compressor, if the quantity of refrigerant Fill with the same quantity + 30.
oil taken from the A/C compressor is between 90 and 150 ml.
Air conditioning (A/C) compressor, if the quantity of refrigerant Fill with the same quantity.
oil taken from the A/C compressor is greater than 150 ml.
Air conditioning (A/C) condenser core Add 30.
Air conditioning (A/C) evaporator core Add 90.
When all lines are renewed. Fill with the same quantity + 2.
When all lines and components are renewed. Add 0.
Every time if refrigerant oil is collected after refrigerant is ex- Fill with the same quantity.
tracted.
Suction accumulator Fill with the same quantity + 90.

Air Conditioning (A/C) Clutch

mm
Air conditioning (A/C) clutch air gap 0.35 - 0.75

Torque Specifications
Description Nm lb-ft lb-in
Air conditioning (A/C) compressor drive plate re- 13 10 -
taining bolt

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412-00-3 Climate Control System - General Information 412-00-3

DIAGNOSIS AND TESTING

Climate Control System

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 412-00 for to read out these faults via the display of the
schematic and connector information. EATC module.
Read-out of current faults
Inspection and Verification On the EATC module, briefly press the "OFF"
and "FOOTWELL" buttons simultaneously, then
1. VERIFY the customer concern.
press "AUTO" within 2 seconds. The self-
2. PERFORM visual inspection for obvious diagnosis which then starts lasts a few seconds.
signs of mechanical or electrical damage. An animated display appears during this time in
the EATC display. Any faults found are displayed
Visual inspection in the form of trouble codes. Example: First of all,
Mechanical Electrical "12" flashes for 2 seconds, then "51" flashes for 2
– Drive belt – Fuses seconds - DTC B1251. If no faults are stored,
then all of the segments in the display are
– Refrigerant lines – Wiring harness actuated. The following table gives information on
– Condenser – Electrical connec- the possible DTCs and their corresponding
tors meanings. Diagnosis mode can be stopped at
3. If an obvious cause for a concern is found any time by PRESSING any button on the EATC
during visual inspection, RECTIFY the cause module.
before performing further tests. CHECK Read-out of intermittent faults
operation of the system.
On the EATC module, briefly press the "OFF"
4. If the concern persists after the visual
and "FOOTWELL" buttons simultaneously, then
inspection, PERFORM a fault diagnosis on
press "FACE LEVEL" within 2 seconds. Any
the climate control system with WDS and
stored intermittent faults are output on the EATC
RECTIFY any displayed faults in accordance
display and should be noted for safety reasons.
with the displayed fault description. CHECK
By PRESSING the "DEFROST" button, the fault
operation of the system.
memory is cleared and diagnosis mode is ended.
5. If no fault is stored in the fault memory, To end diagnosis mode without clearing the
PROCEED with the Symptom Chart DTCs, PRESS any other button on the EATC
according to the fault symptom. module.
Reading out the EATC software version
Fault Memory Interrogation without WDS On the EATC module, briefly ACTUATE the
(Vehicles with EATC System only) "OFF" and "FOOTWELL" buttons simultaneously,
The climate control system features a self- then PRESS "A/C" within 2 seconds. The SW
diagnosis function which can detect and store version is output on the EATC display. The
both current permanent faults as well as output mode is ended by PRESSING any button.
intermittent faults which have occurred during
normal operation of the vehicle. It is also possible
Trouble Code Table (Vehicles with EATC System only)
Self-test code Description Action
B1200 Internal control module fault CLEAR fault memory. If the fault
occurs again after a functional
test, RENEW the EATC module.
B1242 Circuit of heater flap control mo- GO to Pinpoint Test D
tor, recirculated air fault
B1251 Open circuit in interior tempera- GO to Pinpoint Test L
ture sensor circuit

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412-00-4 Climate Control System - General Information 412-00-4

DIAGNOSIS AND TESTING (Continued)

Self-test code Description Action
B1253 Short circuit in interior tempera- GO to Pinpoint Test L
ture sensor circuit (short to
ground)
B1261 Short circuit in sun load sensor GO to Pinpoint Test K
circuit (short to ground)
B1262 Circuit of defrost actuator motor GO to Pinpoint Test E
faulty
B1263 Circuit of dashboard/footwell ac- GO to Pinpoint Test F
tuator motor faulty
B1342 Internal control module fault CLEAR fault memory. If the fault
occurs again after a functional
test, RENEW the EATC module.
B1676 Power supply voltage outside CHECK charging system. For
tolerance further information REFER to
Section 414-00. If the charging
system is OK,
GO to Pinpoint Test I
B2266 Air temperature positioning motor GO to Pinpoint Test G
circuit faulty
B2297 Open circuit in the footwell outlet GO to Pinpoint Test H
temperature sensor circuit
B2298 Short circuit in the footwell outlet GO to Pinpoint Test H
temperature sensor circuit (short
to ground)
B2308 Interior temperature sensor GO to Pinpoint Test M
blower circuit faulty
B2516 Heater blower control module GO to Pinpoint Test J
circuit faulty
Symptom Chart

Condition Possible Sources Action

• Heater blower motor inopera- • Fuse(s) • GO to Pinpoint Test A
tive/partially inoperative (vehi- • Circuit(s)
cles without EATC only) • Heater blower relay
• Heater blower motor
• Heater blower switch
• Heater blower motor variable
resistor
• Heater blower motor running • Heater blower switch • GO to Pinpoint Test B
continuously (vehicles without • Circuit(s)
EATC only) • Heater blower relay

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412-00-5 Climate Control System - General Information 412-00-5

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Air conditioning inoperative • Fuse(s) • GO to Pinpoint Test C
(heater blower function OK) • Circuit(s)
• Heating and air conditioning
control module or EATC module
• A/C compressor clutch diode
• A/C compressor clutch
• Air conditioning wide open
throttle (WOT) relay.
• Refrigerant quantity / circuit
• A/C compressor switch
• Dual pressure switch
• Powertrain control module
(PCM)
• Inadequate cooling performance • Malfunction of the cooling fan • PERFORM a fault diagnosis of
of air conditioning (A/C com- • Refrigerant quantity the electronic engine
pressor clutch function OK) • Refrigerant circuit management (PCM) with WDS.
• CHECK the refrigerant quan-
tity/circuit with the R134a refrig-
erant centre and REPAIR the
system as required.
• Malfunction of the air recircula- • Circuit(s) • GO to Pinpoint Test D
tion flap • Air recirculation flap
• Heater flap positioning motor,
recirculated air
• Heating and air conditioning
control module or EATC module
• Malfunction of the defrost flap • Circuit(s) • GO to Pinpoint Test E
• Defrost flap
• Defrost flap positioning motor
• Malfunction of the air distribution • Circuit(s) • GO to Pinpoint Test F
flap • Air distribution flap
• Dashboard/footwell flap
positioning motor
• Malfunction of the air tempera- • Circuit(s) • GO to Pinpoint Test G
ture flap • Air temperature flap
• Air temperature flap positioning
motor
• Fault in the circuit of the footwell • Circuit(s) • GO to Pinpoint Test H
outlet temperature sensor • Footwell outlet temperature
sensor
• EATC module inoperative (no • Fuse(s) • GO to Pinpoint Test I
display on the climate control • Circuit(s)
assembly) • Central junction box
• Heater blower relay
• EATC module
• Malfunction of the heater blower • Circuit(s) • GO to Pinpoint Test J
(vehicles with EATC only, dis- • EATC module
play on the climate control as- • Heater blower control module
sembly OK)

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412-00-6 Climate Control System - General Information 412-00-6

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Fault in the circuit of the sun • Circuit(s) • GO to Pinpoint Test K
load sensor (vehicles with EATC • Sun load sensor
only)
• Fault in the circuit of the interior • Circuit(s) • GO to Pinpoint Test L
temperature sensor (vehicles • Interior temperature sensor
with EATC only)
• Fault in the circuit of the interior • Fuse • GO to Pinpoint Test M
temperature sensor blower (ve- • Circuit(s)
hicles with EATC only) • Interior temperature sensor

Pinpoint Tests
PINPOINT TEST A: HEATER BLOWER MOTOR INOPERATIVE/PARTIALLY INOPERATIVE
(VEHICLES WITHOUT EATC ONLY)
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: DETERMINE FAULT CONDITIONS
1 Key in ON position.
2 Switch the heater blower switch through all set-
tings.
• Is the heater blower motor inoperative in all
switch positions?
→ Yes
GO to A2
→ No
GO to A14
A2: CHECK FUSE F6
1 Key in OFF position.
2 CHECK fuse F6 (BJB).
• Is the fuse OK?
→ Yes
GO to A3
→ No
RENEW fuse F6 (40 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.
A3: CHECK VOLTAGE AT FUSE F6
1 Connect fuse F6 (BJB).
2 Measure the voltage between fuse F6 (40 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to A4
→ No
RECTIFY the voltage supply to fuse F6 with
the aid of the Wiring Diagrams. CHECK op-
eration of the system.

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412-00-7 Climate Control System - General Information 412-00-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A4: CHECK FUSE F93
1 CHECK fuse F93 (CJB).
• Is the fuse OK?
→ Yes
GO to A5
→ No
RENEW fuse F93 (10 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.
A5: CHECK VOLTAGE AT FUSE F93
1 Connect fuse F93 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F93 (10 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to A6
→ No
RECTIFY the voltage supply to fuse F93
with the aid of the Wiring Diagrams. CHECK
operation of the system.
A6: CHECK THE VOLTAGE AT THE HEATER BLOWER MOTOR
1 Key in OFF position.
2 Disconnect heater blower motor C442.
3 Key in ON position.
4 Measure the voltage between the heater
blower motor, connector C442, pin 1, circuit
15S-FA45 (GN/RD), wiring harness side and
ground.

• Is battery voltage measured?

→ Yes
GO to A11
→ No
GO to A7
A7: CHECK THE VOLTAGE AT THE HEATER BLOWER RELAY
1 Key in OFF position.
2 Disconnect heater blower relay C920 (CJB).

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412-00-8 Climate Control System - General Information 412-00-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the heater
blower relay, socket C920, pin 5, wiring har-
ness side and ground.

• Is battery voltage measured?

→ Yes
GO to A8
→ No
LOCATE and RECTIFY the open circuit be-
tween the heater blower relay and fuse F6
with the aid of the Wiring Diagrams. CHECK
operation of the system.
A8: CHECK THE CONTROL VOLTAGE AT THE HEATER BLOWER RELAY
1 Key in ON position.
2 Measure the voltage between the heater
blower relay, socket C920, pin 2, wiring har-
ness side and ground.

• Is battery voltage measured?

→ Yes
GO to A9
→ No
LOCATE and RECTIFY the open circuit be-
tween the heater blower relay and fuse F93
with the aid of the Wiring Diagrams. CHECK
operation of the system.
A9: CHECK THE GROUND CONNECTION OF THE HEATER BLOWER RELAY
1 Key in OFF position.

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412-00-9 Climate Control System - General Information 412-00-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the heater
blower relay, socket C920, pin 1, wiring har-
ness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to A10
→ No
LOCATE and RECTIFY the open circuit be-
tween the heater blower relay and ground
connection G200 with the aid of the Wiring
Diagrams. CHECK operation of the system.
A10: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER RELAY AND THE HEATER
BLOWER MOTOR FOR OPEN CIRCUIT
1 Measure the resistance between the heater
blower relay, socket C920, pin 3, wiring har-
ness side and the heater blower motor, con-
nector C442, pin 1, circuit 15S-FA45 (GN/RD),
wiring harness side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the heater blower relay. CHECK
operation of the system.
→ No
LOCATE and RECTIFY the open circuit be-
tween the heater blower relay and the
heater blower motor with the aid of the Wir-
ing Diagrams. CHECK operation of the sys-
tem.
A11: CHECK THE GROUND CONNECTION OF THE HEATER BLOWER MOTOR
1 Key in OFF position.
2 Set the heater blower switch to "maximum".

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412-00-10 Climate Control System - General Information 412-00-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the heater
blower motor connector C442, pin 2, circuit
31S-FA45 (BK/OG), wiring harness side and
ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the heater blower motor. CHECK
operation of the system.
→ No
GO to A12
A12: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER MOTOR AND THE HEATER
BLOWER SWITCH FOR OPEN CIRCUIT
1 Disconnect heater blower switch C448.
2 Measure the resistance between the heater
blower motor, connector C442, pin 2, circuit
31S-FA45 (BK/OG), wiring harness side and
the heater blower switch, connector C448, pin
1, circuit 31S-FA33 (BK/OG), wiring harness
side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to A13
→ No
LOCATE and RECTIFY the open circuit in
circuit 31S-FA45 (BK/OG) between the
heater blower motor and soldered connec-
tion S113 with the aid of the Wiring Dia-
grams. CHECK operation of the system.

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412-00-11 Climate Control System - General Information 412-00-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A13: CHECK THE GROUND CONNECTION OF THE HEATER BLOWER SWITCH
1 Measure the resistance between the heater
blower switch, connector C448, pin 3, circuit
31-FA1 (BK), wiring harness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the heater blower switch. CHECK
operation of the system.
→ No
LOCATE and RECTIFY the open circuit in
circuit 31-FA1 (BK) between the heater
blower switch and ground connection G204
with the aid of the Wiring Diagrams. CHECK
operation of the system.
A14: DETERMINE FAULT CONDITIONS
1 Set the heater blower switch to "maximum".
• Is the heater blower motor inoperative?
→ Yes
GO to A15
→ No
GO to A16
A15: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER MOTOR AND THE HEATER
BLOWER SWITCH FOR OPEN CIRCUIT
1 Key in OFF position.
2 Disconnect heater blower switch C448.
3 Disconnect heater blower motor C442.
4 Measure the resistance between the heater
blower motor, connector C442, pin 2, circuit
31S-FA45 (BK/OG), wiring harness side and
the heater blower switch, connector C448, pin
1, circuit 31S-FA33 (BK/OG), wiring harness
side.

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412-00-12 Climate Control System - General Information 412-00-12

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the heater blower switch. CHECK
operation of the system.
→ No
LOCATE and RECTIFY the open circuit in
circuit 31S-FA33 (BK/OG) between soldered
connection S113 and the heater blower
switch with the aid of the Wiring Diagrams.
CHECK operation of the system.
A16: CHECK THE HEATER BLOWER SWITCH
1 Key in OFF position.
2 Disconnect Heater blower switch C448.
3 Key in ON position.
4 Measure the voltage between the heater
blower switch, connector C448, pin 6, circuit
31S-FA32 (BK/BU), wiring harness side and
ground.

5 Measure the voltage between the heater

blower switch, connector C448, pin 2, circuit
31S-FA31 (BK/YE), wiring harness side and
ground.
6 Measure the voltage between the heater
blower switch, connector C448, pin 4, circuit
31S-FA30 (BK/WH), wiring harness side and
ground.
• Is battery voltage measured in all cases?
→ Yes
RENEW the heater blower switch. CHECK
operation of the system.
→ No
GO to A17
A17: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER MOTOR AND THE VARIABLE
HEATER BLOWER RESISTOR.
1 Key in OFF position.
2 Disconnect heater blower variable resistor
C443.
3 Key in ON position.

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412-00-13 Climate Control System - General Information 412-00-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the heater
blower motor variable resistor, connector
C443, pin 1, circuit 31S-FA1 (BK/WH), wiring
harness side and ground.

• Is battery voltage measured?

→ Yes
GO to A18
→ No
LOCATE and RECTIFY the open circuit in
circuit 31S-FA19 (BK/WH) between sol-
dered connection S113 and the heater
blower motor variable resistor with the aid of
the Wiring Diagrams. CHECK operation of
the system.
A18: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER MOTOR VARIABLE RESISTOR
AND THE HEATER BLOWER SWITCH FOR OPEN CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the heater
blower motor variable resistor, connector
C443, pin 4, circuit 31S-FA32 (BK/BU), wiring
harness side and the heater blower switch,
connector C448, pin 6, circuit 31S-FA32
(BK/BU), wiring harness side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to A19
→ No
LOCATE and RECTIFY the open circuit in
circuit 31S-FA32 (BK/BU) between the
heater blower motor variable resistor and
the heater blower switch with the aid of the
Wiring Diagrams. CHECK operation of the
system.

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412-00-14 Climate Control System - General Information 412-00-14

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A19: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER MOTOR VARIABLE RESISTOR
AND THE HEATER BLOWER SWITCH FOR OPEN CIRCUIT
1 Measure the resistance between the heater
blower motor variable resistor, connector
C443, pin 2, circuit 31S-FA31 (BK/YE), wiring
harness side and the heater blower switch,
connector C448, pin 2, circuit 31S-FA31
(BK/YE), wiring harness side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to A20
→ No
LOCATE and RECTIFY the open circuit in
circuit 31S-FA31 (BK/YE) between the
heater blower motor variable resistor and
the heater blower switch with the aid of the
Wiring Diagrams. CHECK operation of the
system.
A20: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER MOTOR VARIABLE RESISTOR
AND THE HEATER BLOWER SWITCH FOR OPEN CIRCUIT
1 Measure the resistance between the heater
blower motor variable resistor, connector
C443, pin 3, circuit 31S-FA30 (BK/WH), wiring
harness side and the heater blower switch,
connector C448, pin 4, circuit 31S-FA30
(BK/WH), wiring harness side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the heater blower motor variable
resistor. CHECK operation of the system.
→ No

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412-00-15 Climate Control System - General Information 412-00-15

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the open circuit in
circuit 31S-FA30 (BK/WH) between the
heater blower motor variable resistor and
the heater blower switch with the aid of the
Wiring Diagrams. CHECK operation of the
system.
PINPOINT TEST B: HEATER BLOWER MOTOR RUNNING CONTINUOUSLY (VEHICLES
WITHOUT EATC ONLY)
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK FAULT CONDITIONS
1 Key in OFF position.
2 Set the heater blower switch to "stage 1".
• Does the heater blower motor run?
→ Yes
GO to B4
→ No
The heater blower motor only runs with the
ignition in the position "ON": GO to B2
B2: CHECK THE HEATER BLOWER SWITCH
1 Disconnect heater blower switch C448.
2 Key in ON position.
• Does the heater blower motor run continu-
ously?
→ Yes
GO to B3
→ No
RENEW the heater blower switch. CHECK
operation of the system.
B3: CHECK THE CIRCUITS BETWEEN THE HEATER BLOWER VARIABLE RESISTOR AND THE
HEATER BLOWER SWITCH FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect heater blower variable resistor
C443.
3 Key in ON position.
• Does the heater blower motor run continu-
ously?
→ Yes
CHECK all circuits that are connected to
soldered connection S113 for a short to
ground with the aid of the Wiring Diagrams
and RECTIFY any short circuit(s) found.
CHECK operation of the system.
→ No
CHECK all circuits between the heater
blower variable resistor and the heater
blower switch for a short to ground with the
aid of the Wiring Diagrams and RECTIFY
any short circuit(s) found. CHECK operation
of the system.
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412-00-16 Climate Control System - General Information 412-00-16

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B4: CHECK THE CONTROL VOLTAGE AT THE HEATER BLOWER RELAY
1 Disconnect heater blower relay C920 (CJB).
2 Measure the voltage between the heater
blower relay, socket C920, pin 2, wiring har-
ness side and ground.

• Is a voltage registered?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to fuse F93
with the aid of the Wiring Diagrams. CHECK
operation of the system.
→ No
GO to B5
B5: CHECK THE VOLTAGE AT THE HEATER BLOWER RELAY
1 Measure the voltage between the heater
blower relay, socket C920, pin 3, wiring har-
ness side and ground.

• Is a voltage registered?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits between the heater
blower relay and the heater blower motor
with the aid of the Wiring Diagrams. CHECK
operation of the system.
→ No
RENEW the heater blower relay. CHECK
operation of the system.

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412-00-17 Climate Control System - General Information 412-00-17

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: AIR CONDITIONING INOPERATIVE (HEATER BLOWER FUNCTION OK)

CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE ELECTRONIC ENGINE MANAGEMENT (PCM) WITH WDS
1 Key in OFF position.
2 Connect the diagnostic tool.
3 Key in START position.
4 Perform fault diagnosis on the electronic en-
gine management (PCM) with WDS.
• Are any faults displayed?
→ Yes
RECTIFY the faults according to the WDS
instructions. CHECK operation of the sys-
tem.
→ No
GO to C2
C2: CHECK FUSE F31
1 Key in OFF position.
2 CHECK fuse F31 (BJB).
• Is the fuse OK?
→ Yes
GO to C3
→ No
RENEW fuse F31 (7.5 A). If the fuse blows
again after switching on the air conditioning,
CHECK the A/C compressor clutch diode
and RENEW as necessary. If the diode is
OK, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
CHECK operation of the system.
C3: CHECK VOLTAGE AT FUSE F31
1 Connect fuse F31 (BJB).
2 Measure the voltage between fuse F31 (7.5 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to C4
→ No
RECTIFY the voltage supply to fuse F31
with the aid of the Wiring Diagrams. CHECK
operation of the system.
C4: CHECK FUSE F82
1 CHECK fuse F82 (CJB).
• Is the fuse OK?
→ Yes
GO to C5
→ No

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412-00-18 Climate Control System - General Information 412-00-18

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
RENEW fuse F82 (7.5 A). If the fuse blows
again, LOCATE and RECTIFY the short to
ground using the Wiring Diagrams. CHECK
operation of the system.
C5: CHECK VOLTAGE AT FUSE F82
1 Connect fuse F82 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F82 (7.5 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to C6
→ No
RECTIFY the voltage supply to fuse F82
with the aid of the Wiring Diagrams. CHECK
operation of the system.
C6: CHECK THE VOLTAGE SUPPLY AT THE A/C SYSTEM WIDE OPEN THROTTLE RELAY
(WOT)
1 Key in OFF position.
2 Disconnect A/C WOT relay C906 (BJB).
3 Measure the voltage between the A/C WOT
relay, socket C906, pin 5, circuit 30-FA12
(GN/BU), wiring harness side and ground.

• Is battery voltage measured?

→ Yes
GO to C7
→ No
LOCATE and RECTIFY the open circuit in
circuit 30-FA12 (GN/BU) between fuse F31
and the A/C WOT relay with the aid of the
Wiring Diagrams. CHECK operation of the
system.
C7: CHECK THE CONTROL VOLTAGE AT THE A/C WOT RELAY
1 Key in ON position.

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412-00-19 Climate Control System - General Information 412-00-19

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the A/C WOT
relay, socket C906, pin 2, circuit 15-FA11
(GN/YE), wiring harness side and ground.

• Is battery voltage measured?

→ Yes
GO to C8
→ No
LOCATE and RECTIFY the open circuit in
circuit 15-FA11 (GN/YE) between soldered
connection S437 and the A/C WOT relay
with the aid of the Wiring Diagrams. CHECK
operation of the system.
C8: CHECK THE A/C COMPRESSOR CLUTCH CIRCUIT
1 Key in OFF position.
2 Use a fused test cable (7,5 A) to bridge the
A/C WOT relay, socket C906, pins 3 and 5,
wiring harness side.

3 Check the operation of the A/C compressor

clutch.
• Does the A/C compressor clutch operate?
→ Yes
GO to C11
→ No
GO to C9
C9: CHECK THE CIRCUIT BETWEEN THE A/C WOT RELAY AND THE A/C COMPRESSOR
CLUTCH FOR OPEN CIRCUIT
1 Disconnect A/C compressor clutch C101 (vehi-
cles with diesel engines: C104).

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412-00-20 Climate Control System - General Information 412-00-20

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the A/C WOT
relay, socket C906, pin 3, circuit 15S-FA12
(RD/BU), wiring harness side and the A/C
compressor clutch, connector C101 (vehicles
with diesel engines: C104), pin 1, circuit 15S-
FA6 (GN/YE), wiring harness side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to C10
→ No
LOCATE and RECTIFY the open circuit be-
tween the A/C WOT relay and the A/C com-
pressor clutch with the aid of the Wiring
Diagrams. CHECK operation of the system.
C10: CHECK THE GROUND CONNECTION OF THE A/C COMPRESSOR CLUTCH
1 Measure the resistance between the A/C com-
pressor clutch, connector C101 (vehicles with
diesel engines: C104), pin 2, circuit 31-FA6
(BK), wiring harness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the A/C compressor clutch.
CHECK operation of the system.
→ No
LOCATE and RECTIFY the open circuit be-
tween the A/C compressor clutch and
ground connection G102 with the aid of the
Wiring Diagrams. CHECK operation of the
system.
C11: CHECK THE A/C WOT RELAY
1 Check the A/C WOT relay according to the
component check at the end of this section.
• Is the A/C WOT relay OK?

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412-00-21 Climate Control System - General Information 412-00-21

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to C12
→ No
RENEW the A/C WOT relay. CHECK and if
necessary RENEW the A/C compressor
clutch diode. CHECK operation of the sys-
tem.
C12: CHECK THE CONTROL VOLTAGE AT THE POWERTRAIN CONTROL MODULE (PCM)
1 Disconnect PCM C100.
2 Key in ON position.
3 Measure the voltage between the PCM, con-
nector C100, pin 41, circuit 15S-FA12
(GN/BU), wiring harness side and ground.

• Is battery voltage measured?

→ Yes
GO to C18
→ No
GO to C13
C13: CHECK THE REFRIGERANT QUANTITY
1 Key in OFF position.
2 Check the quantity of refrigerant in the sys-
tem.REFER to Section 412-00.
• Is the quantity of refrigerant in the system in
accordance with the manufacturer's specifica-
tions?
→ Yes
GO to C14
→ No
FILL the system with the correct quantity of
refrigerant. CHECK the system for leaks
and CHECK the operation of the system.
C14: CHECK THE VOLTAGE AT THE A/C COMPRESSOR SWITCH
1 Disconnect A/C compressor switch C105.
2 Key in ON position.

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412-00-22 Climate Control System - General Information 412-00-22

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the A/C com-
pressor switch, connector C105, pin 4, circuit
15-FA17 (GN/OG), wiring harness side and
ground.

• Is battery voltage measured?

→ Yes
GO to C15
→ No
LOCATE and RECTIFY the open circuit be-
tween the A/C compressor switch and fuse
F82 with the aid of the Wiring Diagrams.
CHECK operation of the system.
C15: CHECK THE A/C COMPRESSOR SWITCH
1 Key in OFF position.
2 Measure the resistance at the A/C compressor
switch, connector C105, between pin 1 and pin
4, component side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to C16
→ No
RENEW the A/C compressor switch.
CHECK operation of the system.
C16: CHECK THE VOLTAGE AT THE DUAL PRESSURE SWITCH
1 Connect A/C compressor switch C105.
2 Disconnect dual pressure switch C134.
3 Key in ON position.

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412-00-23 Climate Control System - General Information 412-00-23

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the dual pres-
sure switch, connector C134, pin 1, circuit 15S-
FA17 (GN/OG) (vehicles with EATC system:
circuit 15S-FA17A (GN/OG)), wiring harness
side and ground.

• Is battery voltage measured?

→ Yes
GO to C17
→ No
LOCATE and RECTIFY open circuit in 15S-
FA17 (GN/OG) (vehicles with EATC system:
circuit 15S-FA17A (GN/OG)) between the
A/C compressor switch and the dual pres-
sure switch with the aid of the Wiring Dia-
grams. CHECK operation of the system.
C17: CHECK THE DUAL PRESSURE SWITCH
1 Key in OFF position.
2 Measure the resistance at the dual pressure
switch, connector C134, between pin 1 and pin
4, component side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
LOCATE and RECTIFY the open circuit in
15S-FA12 (GN/BU) between the PCM and
the dual pressure switch with the aid of the
Wiring Diagrams. CHECK operation of the
system.
→ No
CHECK the system pressure in the refriger-
ant circuit. If the system pressure is OK,
RENEW the dual pressure switch. CHECK
operation of the system.

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412-00-24 Climate Control System - General Information 412-00-24

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C18: CHECK THE CIRCUIT BETWEEN THE PCM AND THE A/C WOT RELAY
1 Key in OFF position.
2 Measure the resistance between the PCM,
connector C100, pin 69, circuit 91S-FA11
(BK/YE), wiring harness side and the A/C WOT
relay, socket C906, pin 1, wiring harness side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
Vehicles with EATC system: CHECK the
PCM and RENEW if necessary. CHECK
operation of the system.
Vehicles without EATC system: GO to C19
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the PCM and the A/C WOT re-
lay with the aid of the Wiring Diagrams.
CHECK operation of the system.
C19: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER SWITCH AND THE HEATING
AND AIR CONDITIONING CONTROL MODULE FOR OPEN CIRCUIT
1 Disconnect heating and air conditioning control
module C539a.
2 Set the heater blower switch to "stage 1".
3 Measure the resistance between the heating
and air conditioning control module, connector
C539a, pin 1, circuit 31S-FA30A (BK/WH), wir-
ing harness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to C20
→ No

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412-00-25 Climate Control System - General Information 412-00-25

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the open circuit in
31S-FA30A (BK/WH) between the heater
blower switch and the heating and air condi-
tioning control module with the aid of the
Wiring Diagrams. CHECK operation of the
system.
C20: CHECK THE CIRCUIT BETWEEN THE HEATER BLOWER SWITCH AND THE HEATING
AND AIR CONDITIONING CONTROL MODULE FOR A SHORT TO VOLTAGE SUPPLY
1 Disconnect heater blower switch C448.
2 Key in ON position.
3 Measure the voltage between the heating and
air conditioning control module, connector
C539a, pin 1, circuit 31S-FA30A (BK/WH), wir-
ing harness side and ground.

• Is a voltage registered?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in circuit 31S-FA30A (BK/WH) be-
tween the heater blower switch and the
heating and air conditioning control module
with the aid of the Wiring Diagrams. CHECK
operation of the system.
→ No
GO to C21
C21: CHECK THE HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Connect heater blower switch C448.
3 Connect A/C WOT Relay C906.
4 Connect PCM C100.
5 Key in START position.
6 Check the operation of the A/C compressor
clutch.
• Does the A/C compressor clutch operate?
→ Yes
CHECK the heating and air conditioning
control module and RENEW if necessary.
CHECK operation of the system.
→ No
CHECK the PCM and RENEW if necessary.
CHECK operation of the system.

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412-00-26 Climate Control System - General Information 412-00-26

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST D: MALFUNCTION OF THE AIR RECIRCULATION FLAP
CONDITIONS DETAILS/RESULTS/ACTIONS
NOTE: The air recirculation flap is actuated by means of a DC motor. This motor is actuated by the
EATC module or the heating and air conditioning module for a maximum of 7 seconds after pressing
the air recirculation button. Opening and closing of the air recirculation flap is performed by reversing
the polarity of the applied voltage.
NOTE: Air recirculation mode is not available when the "Defrost/demist windscreen" function is active.
D1: CHECK THE VOLTAGE AT THE HEATER FLAP POSITIONING MOTOR FOR
RECIRCULATED AIR
1 Key in OFF position.
2 Disconnect heater flap positioning motor, recir-
culated air C538.
3 Key in ON position.
4 Measure the voltage at the heater flap position-
ing motor for recirculated air, connector C538,
between pin 2 and pin 4, wiring harness side.

5 Press the recirculated air button several times

during the measurement.
• Is a voltage of at least 10 V measured with al-
ternating polarity?
→ Yes
CHECK the air recirculation flap for ease of
movement and correct operation. If the air
recirculation flap is OK, RENEW the heater
flap positioning motor for recirculated air.
CHECK operation of the system.
→ No
GO to D2
D2: CHECK FOR OPEN CIRCUIT BETWEEN HEATER FLAP POSITIONING MOTOR FOR
RECIRCULATED AIR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL
MODULE
1 Key in OFF position.
2 Disconnect EATC module or heating and air
conditioning control module C539a.

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412-00-27 Climate Control System - General Information 412-00-27

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the heater
flap positioning motor for recirculated air, con-
nector C538 and pin 2 (right-hand drive vehi-
cles: pin 4), circuit 33-FA76 (YE/BU), wiring
harness side and the EATC module or the
heating and air conditioning control module,
connector C539a, pin 4, circuit 33-FA76
(YE/BU), wiring harness side.

4 Measure the resistance between the heater

flap positioning motor for recirculated air, con-
nector C538, pin 4 (right-hand drive vehicles:
pin 2), circuit 32-FA76 (WH/BU), wiring har-
ness side and the EATC module or the heating
and air conditioning control module, connector
C539a, pin 5, circuit 32-FA76 (WH/BU), wiring
harness side.

• Is a resistance of less than 2 Ohms measured

in both cases?
→ Yes
GO to D3
→ No
LOCATE and RECTIFY the open circuit in
33-FA76 (YE/BU) or 32-FA76 (WH/BU) be-
tween the heater flap positioning motor for
recirculated air and the EATC module or the
heating and air conditioning control module
with the aid of the Wiring Diagrams. CHECK
operation of the system.
D3: CHECK FOR SHORT TO VOLTAGE SUPPLY BETWEEN HEATER FLAP POSITIONING
MOTOR FOR RECIRCULATED AIR AND EATC MODULE OR HEATING AND AIR CONDITIONING
CONTROL MODULE
1 Key in ON position.

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412-00-28 Climate Control System - General Information 412-00-28

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the EATC mod-
ule or the heating and air conditioning control
module, connector C539a, pin 4, circuit 33-
FA76 (YE/BU), wiring harness side and
ground.

3 Measure the voltage between the EATC mod-

ule or the heating and air conditioning control
module, connector C539a, pin 5, circuit 32-
FA76 (WH/BU), wiring harness side and
ground.
• Is a voltage measured during any of these
measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in circuit 33-FA76 (YE/BU) or 32-
FA76 (WH/BU) between the heater flap po-
sitioning motor for recirculated air and the
EATC module or the heating and air condi-
tioning control module with the aid of the
Wiring Diagrams. CHECK operation of the
system.
→ No
GO to D4
D4: CHECK FOR SHORT TO GROUND BETWEEN HEATER FLAP POSITIONING MOTOR FOR
RECIRCULATED AIR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL
MODULE
1 Key in OFF position.
2 Measure the resistance between the EATC
module or the heating and air conditioning con-
trol module, connector C539a, pin 4, circuit 33-
FA76 (YE/BU), wiring harness side and
ground.

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412-00-29 Climate Control System - General Information 412-00-29

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the EATC
module or the heating and air conditioning con-
trol module, connector C539a, pin 5, circuit 32-
FA76 (WH/BU), wiring harness side and
ground.
• Is a resistance greater than 10 kOhm meas-
ured in both cases?
→ Yes
CHECK the EATC module or the heating
and air conditioning control module and if
necessary RENEW. CHECK operation of
the system.
→ No
LOCATE and RECTIFY the short to ground
in circuit 33-FA76 (YE/BU) or 32-FA76
(WH/BU) between the heater flap position-
ing motor for recirculated air and the EATC
module or the heating and air conditioning
control module with the aid of the Wiring
Diagrams. CHECK operation of the system.
PINPOINT TEST E: MALFUNCTION OF THE DEFROST FLAP
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK FOR OPEN CIRCUIT BETWEEN DEFROST FLAP POSITIONING MOTOR AND EATC
MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Disconnect EATC module or heating and air
conditioning control module C539a.
3 Disconnect defrost flap positioning motor
C532.
4 Measure the resistance between the defrost
flap positioning motor, connector C532, pin 1,
circuit 31S-FB15 (BK/OG), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 6, circuit 31S-FB15 (BK/OG), wiring har-
ness side.

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412-00-30 Climate Control System - General Information 412-00-30

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the resistance between the defrost
flap positioning motor, connector C532, pin 2,
circuit 31S-FB14 (BK/BU), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 13, circuit 31S-FB14 (BK/BU), wiring har-
ness side.

6 Measure the resistance between the defrost

flap positioning motor, connector C532, pin 3,
circuit 31S-FB16 (BK/GN), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 7, circuit 31S-FB16 (BK/GN), wiring har-
ness side.

7 Measure the resistance between the defrost

flap positioning motor, connector C532, pin 4,
circuit 31S-FB17 (BK/RD), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 20, circuit 31S-FB17 (BK/RD), wiring har-
ness side.

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412-00-31 Climate Control System - General Information 412-00-31

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
8 Measure the resistance between the defrost
flap positioning motor, connector C532, pin 6,
circuit 31S-FB18 (BK/WH), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 21, circuit 31S-FB18 (BK/WH), wiring har-
ness side.

• Is a resistance of less than 2 Ohms measured

following all of the measurements?
→ Yes
GO to E2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit between the defrost flap posi-
tioning motor and the EATC module or the
heating and air conditioning control module
with the aid of the Wiring Diagrams. CHECK
operation of the system.
E2: CHECK FOR SHORT TO VOLTAGE SUPPLY BETWEEN DEFROST FLAP POSITIONING
MOTOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in ON position.
2 Measure the voltage between the defrost flap
positioning motor, connector C532, pin 1, cir-
cuit 31S-FB15 (BK/OG), wiring harness side
and ground.

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412-00-32 Climate Control System - General Information 412-00-32

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the defrost flap
positioning motor, connector C532, pin 2, cir-
cuit 31S-FB14 (BK/BU), wiring harness side
and ground.

4 Measure the voltage between the defrost flap

positioning motor, connector C532, pin 3, cir-
cuit 31S-FB16 (BK/GN), wiring harness side
and ground.

5 Measure the voltage between the defrost flap

positioning motor, connector C532, pin 4, cir-
cuit 31S-FB17 (BK/RD), wiring harness side
and ground.

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412-00-33 Climate Control System - General Information 412-00-33

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Measure the voltage between the defrost flap
positioning motor, connector C532, pin 6, cir-
cuit 31S-FB18 (BK/WH), wiring harness side
and ground.

• Is a voltage measured during any of these

measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the affected circuit between the
defrost flap positioning motor and the EATC
module or the heating and air conditioning
control module with the aid of the Wiring
Diagrams. CHECK operation of the system.
→ No
GO to E3
E3: CHECK FOR SHORT TO GROUND BETWEEN DEFROST FLAP POSITIONING MOTOR AND
EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Measure the resistance between the defrost
flap positioning motor, connector C532, pin 1,
circuit 31S-FB15 (BK/OG), wiring harness side
and ground.

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412-00-34 Climate Control System - General Information 412-00-34

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the defrost
flap positioning motor, connector C532, pin 2,
circuit 31S-FB14 (BK/BU), wiring harness side
and ground.

4 Measure the resistance between the defrost

flap positioning motor, connector C532, pin 3,
circuit 31S-FB16 (BK/GN), wiring harness side
and ground.

5 Measure the resistance between the defrost

flap positioning motor, connector C532, pin 4,
circuit 31S-FB17 (BK/RD), wiring harness side
and ground.

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412-00-35 Climate Control System - General Information 412-00-35

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Measure the resistance between the defrost
flap positioning motor, connector C532, pin 6,
circuit 31S-FB18 (BK/WH), wiring harness side
and ground.

• Is a resistance of more than 10 kOhms meas-

ured in all of the measurements?
→ Yes
CHECK the defrost flap for ease of move-
ment and proper function. If the defrost flap
is OK, RENEW the defrost flap positioning
motor. CHECK operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit between the defrost
flap positioning motor and the EATC module
or the heating and air conditioning control
module with the aid of the Wiring Diagrams.
CHECK operation of the system.
PINPOINT TEST F: MALFUNCTION OF THE AIR DISTRIBUTION FLAP
CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK FOR OPEN CIRCUIT BETWEEN DASHBOARD/FOOTWELL FLAP POSITIONING
MOTOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Disconnect EATC module or heating and air
conditioning control module C539a.
3 Disconnect dashboard/footwell flap positioning
motor C533.
4 Measure the resistance between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 1, circuit 31S-FB20 (BK/BU),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539a, pin 8, circuit 31S-FB20
(BK/BU), wiring harness side.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the resistance between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 2, circuit 31S-FB19 (BK/YE),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539a, pin 26, circuit 31S-FB19
(BK/YE), wiring harness side.

6 Measure the resistance between the

dashboard/footwell flap positioning motor, con-
nector C533, pin 3, circuit 31S-FB21 (BK/OG),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539a, pin 9, circuit 31S-FB21
(BK/OG), wiring harness side.

7 Measure the resistance between the

dashboard/footwell flap positioning motor, con-
nector C533, pin 4, circuit 31S-FB22 (BK/GN),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539a, pin 22, circuit 31S-FB22
(BK/GN), wiring harness side.

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412-00-37 Climate Control System - General Information 412-00-37

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
8 Measure the resistance between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 6, circuit 31S-FB23 (BK/RD),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539a, pin 23, circuit 31S-FB23
(BK/RD), wiring harness side.

• Is a resistance of less than 2 Ohms measured

following all of the measurements?
→ Yes
GO to F2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit between the
dashboard/footwell flap positioning motor
and the EATC module or the heating and air
conditioning control module with the aid of
the Wiring Diagrams. CHECK operation of
the system.
F2: CHECK FOR SHORT TO VOLTAGE SUPPLY BETWEEN DASHBOARD/FOOTWELL FLAP
POSITIONING MOTOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL
MODULE
1 Key in ON position.
2 Measure the voltage between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 1, circuit 31S-FB20 (BK/BU),
wiring harness side and ground.

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412-00-38 Climate Control System - General Information 412-00-38

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 2, circuit 31S-FB19 (BK/YE),
wiring harness side and ground.

4 Measure the voltage between the

dashboard/footwell flap positioning motor, con-
nector C533, pin 3, circuit 31S-FB21 (BK/OG),
wiring harness side and ground.

5 Measure the voltage between the

dashboard/footwell flap positioning motor, con-
nector C533, pin 4, circuit 31S-FB22 (BK/GN),
wiring harness side and ground.

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412-00-39 Climate Control System - General Information 412-00-39

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Measure the voltage between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 6, circuit 31S-FB23 (BK/RD),
wiring harness side and ground.

• Is a voltage measured during any of these

measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the affected circuit between the
dashboard/footwell flap positioning motor
and the EATC module or the heating and air
conditioning control module with the aid of
the Wiring Diagrams. CHECK operation of
the system.
→ No
GO to F3
F3: CHECK FOR SHORT TO GROUND BETWEEN DASHBOARD/FOOTWELL FLAP
POSITIONING MOTOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL
MODULE
1 Key in OFF position.
2 Measure the resistance between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 1, circuit 31S-FB20 (BK/BU),
wiring harness side and ground.

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412-00-40 Climate Control System - General Information 412-00-40

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 2, circuit 31S-FB19 (BK/YE),
wiring harness side and ground.

4 Measure the resistance between the

dashboard/footwell flap positioning motor, con-
nector C533, pin 3, circuit 31S-FB21 (BK/OG),
wiring harness side and ground.

5 Measure the resistance between the

dashboard/footwell flap positioning motor, con-
nector C533, pin 4, circuit 31S-FB22 (BK/GN),
wiring harness side and ground.

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412-00-41 Climate Control System - General Information 412-00-41

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Measure the resistance between the
dashboard/footwell flap positioning motor, con-
nector C533, pin 6, circuit 31S-FB23 (BK/RD),
wiring harness side and ground.

• Is a resistance of more than 10 kOhms meas-

ured in all of the measurements?
→ Yes
CHECK the air distribution flap for ease of
movement and proper function. If the air dis-
tribution flap is OK, RENEW the defrost flap
positioning motor. CHECK operation of the
system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit between the
dashboard/footwell flap positioning motor
and the EATC module or the heating and air
conditioning control module with the aid of
the Wiring Diagrams. CHECK operation of
the system.
PINPOINT TEST G: MALFUNCTION OF THE AIR TEMPERATURE FLAP
CONDITIONS DETAILS/RESULTS/ACTIONS
G1: CHECK FOR OPEN CIRCUIT BETWEEN AIR TEMPERATURE FLAP POSITIONING MOTOR
AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Disconnect EATC module or heating and air
conditioning control module C539a.
3 Disconnect air temperature flap positioning
motor C534.

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412-00-42 Climate Control System - General Information 412-00-42

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between the air tem-
perature flap positioning motor, connector
C534, pin 1, circuit 31S-FB10 (BK/GN), wiring
harness side and the EATC module or the
heating and air conditioning control module,
connector C539a, pin 10, circuit 31S-FB10
(BK/GN), wiring harness side.

5 Measure the resistance between the air tem-

perature flap positioning motor, connector
C534, pin 2, circuit 31S-FB9 (BK/OG), wiring
harness side and the EATC module or the
heating and air conditioning control module,
connector C539a, pin 12, circuit 31S-FB9
(BK/OG), wiring harness side.

6 Measure the resistance between the air tem-

perature flap positioning motor, connector
C534, pin 3, circuit 31S-FB11 (BK/RD), wiring
harness side and the EATC module or the
heating and air conditioning control module,
connector C539a, pin 11, circuit 31S-FB11
(BK/RD), wiring harness side.

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412-00-43 Climate Control System - General Information 412-00-43

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
7 Measure the resistance between the air tem-
perature flap positioning motor, connector
C534, pin 4, circuit 31S-FB12 (BK/WH), wiring
harness side and the EATC module or the
heating and air conditioning control module,
connector C539a, pin 24, circuit 31S-FB12
(BK/WH), wiring harness side.

8 Measure the resistance between the air tem-

perature flap positioning motor, connector
C534, pin 6, circuit 31S-FB13 (BK/YE), wiring
harness side and the EATC module or the
heating and air conditioning control module,
connector C539a, pin 25, circuit 31S-FB13
(BK/YE), wiring harness side.

• Is a resistance of less than 2 Ohms measured

following all of the measurements?
→ Yes
GO to G2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit between the air temperature
flap positioning motor and the EATC module
or the heating and air conditioning control
module with the aid of the Wiring Diagrams.
CHECK operation of the system.
G2: CHECK FOR SHORT TO VOLTAGE SUPPLY BETWEEN AIR TEMPERATURE FLAP
POSITIONING MOTOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL
MODULE
1 Key in ON position.

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412-00-44 Climate Control System - General Information 412-00-44

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the air tempera-
ture flap positioning motor, connector C534,
pin 1, circuit 31S-FB10 (BK/GN), wiring har-
ness side and ground.

3 Measure the voltage between the air tempera-

ture flap positioning motor, connector C534,
pin 2, circuit 31S-FB9 (BK/OG), wiring harness
side and ground.

4 Measure the voltage between the air tempera-

ture flap positioning motor, connector C534,
pin 3, circuit 31S-FB11 (BK/RD), wiring har-
ness side and ground.

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412-00-45 Climate Control System - General Information 412-00-45

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the air tempera-
ture flap positioning motor, connector C534,
pin 4, circuit 31S-FB12 (BK/WH), wiring har-
ness side and ground.

6 Measure the voltage between the air tempera-

ture flap positioning motor, connector C534,
pin 6, circuit 31S-FB13 (BK/YE), wiring har-
ness side and ground.

• Is a voltage measured during any of these

measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the affected circuit between the air
temperature flap positioning motor and the
EATC module or the heating and air condi-
tioning control module with the aid of the
Wiring Diagrams. CHECK operation of the
system.
→ No
GO to G3
G3: CHECK FOR SHORT TO GROUND BETWEEN AIR TEMPERATURE FLAP POSITIONING
MOTOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.

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412-00-46 Climate Control System - General Information 412-00-46

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the air tem-
perature flap positioning motor, connector
C534, pin 1, circuit 31S-FB10 (BK/GN), wiring
harness side and ground.

3 Measure the resistance between the air tem-

perature flap positioning motor, connector
C534, pin 2, circuit 31S-FB9 (BK/OG), wiring
harness side and ground.

4 Measure the resistance between the air tem-

perature flap positioning motor, connector
C534, pin 3, circuit 31S-FB11 (BK/RD), wiring
harness side and ground.

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412-00-47 Climate Control System - General Information 412-00-47

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the resistance between the air tem-
perature flap positioning motor, connector
C534, pin 4, circuit 31S-FB12 (BK/WH), wiring
harness side and ground.

6 Measure the resistance between the air tem-

perature flap positioning motor, connector
C534, pin 6, circuit 31S-FB13 (BK/YE), wiring
harness side and ground.

• Is a resistance of more than 10 kOhms meas-

ured in all of the measurements?
→ Yes
CHECK the air temperature flap for ease of
movement and proper function. If the air
temperature flap is OK, RENEW the air
temperature flap positioning motor. CHECK
operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit between the air tem-
perature flap positioning motor and the
EATC module or the heating and air condi-
tioning control module with the aid of the
Wiring Diagrams. CHECK operation of the
system.
PINPOINT TEST H: FAULT IN THE CIRCUIT OF THE FOOTWELL OUTLET TEMPERATURE
SENSOR
CONDITIONS DETAILS/RESULTS/ACTIONS
H1: CHECK FOR OPEN CIRCUIT BETWEEN FOOTWELL OUTLET TEMPERATURE SENSOR
AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Disconnect EATC module or heating and air
conditioning control module C539a.

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412-00-48 Climate Control System - General Information 412-00-48

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect footwell outlet temperature sensor
C535.
4 Measure the resistance between the footwell
outlet temperature sensor, connector C535, pin
1, circuit 8-FA47 (WH/GN), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 15, circuit 8-FA47 (WH/GN), wiring harness
side.

5 Measure the resistance between the footwell

outlet temperature sensor, connector C535, pin
2, circuit 9-FA47 (BN/GN), wiring harness side
and the EATC module or the heating and air
conditioning control module, connector C539a,
pin 16, circuit 9-FA47 (BN/GN) (vehicles with
EATC system: circuit 9-FA48A (BN/GN)), wir-
ing harness side.

• Is a resistance of less than 2 Ohms measured

in both cases?
→ Yes
GO to H2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit between the footwell outlet
temperature sensor and the EATC module
or the heating and air conditioning control
module with the aid of the Wiring Diagrams.
CHECK operation of the system.
H2: CHECK FOR SHORT TO VOLTAGE SUPPLY BETWEEN FOOTWELL OUTLET
TEMPERATURE SENSOR AND EATC MODULE OR HEATING AND AIR CONDITIONING
CONTROL MODULE
1 Disconnect EATC module C539b (vehicles
with EATC only).
2 Key in ON position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the footwell out-
let temperature sensor, connector C535, pin 1,
circuit 8-FA47 (WH/GN), wiring harness side
and ground.

4 Measure the voltage between the footwell out-

let temperature sensor, connector C535, pin 2,
circuit 9-FA47 (BN/GN), wiring harness side
and ground.
• Is a voltage measured during any of these
measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the affected circuit between the
footwell outlet temperature sensor and the
EATC module or the heating and air condi-
tioning control module with the aid of the
Wiring Diagrams. CHECK operation of the
system.
→ No
GO to H3
H3: CHECK FOR SHORT TO GROUND BETWEEN FOOTWELL OUTLET TEMPERATURE
SENSOR AND EATC MODULE OR HEATING AND AIR CONDITIONING CONTROL MODULE
1 Key in OFF position.
2 Measure the resistance between the footwell
outlet temperature sensor, connector C535, pin
1, circuit 8-FA47 (WH/GN), wiring harness side
and ground.

3 Measure the resistance between the footwell

outlet temperature sensor, connector C535, pin
2, circuit 9-FA47 (BN/GN), wiring harness side
and ground.

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412-00-50 Climate Control System - General Information 412-00-50

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is a resistance greater than 10 kOhm meas-

ured in both cases?
→ Yes
RENEW the footwell outlet temperature
sensor. CHECK operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit between the footwell
outlet temperature sensor and the EATC
module or the heating and air conditioning
control module with the aid of the Wiring
Diagrams. CHECK operation of the system.
PINPOINT TEST I: EATC MODULE INOPERATIVE (NO DISPLAY ON THE CLIMATE CONTROL
ASSEMBLY)
CONDITIONS DETAILS/RESULTS/ACTIONS
I1: CHECK FUSE F65
1 Key in OFF position.
2 CHECK fuse F65 (CJB).
• Is the fuse OK?
→ Yes
GO to I2
→ No
RENEW fuse F65 (7.5 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.
I2: CHECK VOLTAGE AT FUSE F65
1 Connect fuse F65 (CJB).
2 Measure the voltage between fuse F65 (7.5 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to I3
→ No
RECTIFY the voltage supply to fuse F65
with the aid of the Wiring Diagrams. CHECK
operation of the system.
I3: CHECK FUSE F76
1 CHECK fuse F76 (CJB).
• Is the fuse OK?
→ Yes
GO to I4
→ No
RENEW fuse F76 (7.5 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.

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412-00-51 Climate Control System - General Information 412-00-51

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
I4: CHECK VOLTAGE AT FUSE F76
1 Connect fuse F76 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F76 (7.5 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to I14
→ No
GO to I5
I5: CHECK THE HEATER BLOWER MOTOR FOR LIMITED OPERATION
1 Check the operation of the heater blower mo-
tor.
• Is the heater blower motor running at approxi-
mately 50 % power?
→ Yes
LOCATE and RECTIFY the open circuit be-
tween the heater blower relay and fuse F76
in the central junction box with the aid of the
Wiring Diagrams; if necessary RENEW the
central junction box. CHECK operation of
the system.
→ No
GO to I6
I6: CHECK FUSE F6
1 Key in OFF position.
2 CHECK fuse F6 (BJB).
• Is the fuse OK?
→ Yes
GO to I7
→ No
RENEW fuse F6 (40 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.
I7: CHECK VOLTAGE AT FUSE F6
1 Connect fuse F6 (BJB).
2 Measure the voltage between fuse F6 (40 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to I8
→ No
RECTIFY the voltage supply to fuse F6 with
the aid of the Wiring Diagrams. CHECK op-
eration of the system.
I8: CHECK FUSE F93
1 CHECK fuse F93 (CJB).

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412-00-52 Climate Control System - General Information 412-00-52

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the fuse OK?

→ Yes
GO to I9
→ No
RENEW fuse F93 (10 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.
I9: CHECK VOLTAGE AT FUSE F93
1 Connect fuse F93 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F93 (10 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to I10
→ No
RECTIFY the voltage supply to fuse F93
with the aid of the Wiring Diagrams. CHECK
operation of the system.
I10: CHECK THE VOLTAGE AT THE HEATER BLOWER RELAY
1 Key in OFF position.
2 Disconnect heater blower relay C920.
3 Measure the voltage between the heater
blower relay, socket C920, pin 5, wiring har-
ness side and ground.

• Is battery voltage measured?

→ Yes
GO to I11
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F6 and the heater blower
relay with the aid of the Wiring Diagrams.
CHECK operation of the system.
I11: CHECK THE CONTROL VOLTAGE AT THE HEATER BLOWER RELAY
1 Key in ON position.

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412-00-53 Climate Control System - General Information 412-00-53

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the heater
blower relay, socket C920, pin 2, wiring har-
ness side and ground.

• Is battery voltage measured?

→ Yes
GO to I12
→ No
LOCATE and RECTIFY the open circuit be-
tween fuse F93 and the heater blower relay
with the aid of the Wiring Diagrams. CHECK
operation of the system.
I12: CHECK THE GROUND CONNECTION OF THE HEATER BLOWER RELAY
1 Key in OFF position.
2 Measure the resistance between the heater
blower relay, socket C920, pin 1, wiring har-
ness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to I13
→ No
LOCATE and REPAIR the open circuit be-
tween the heater blower relay and ground
connection G200 with the aid of the Wiring
Diagrams. CHECK operation of the system.

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412-00-54 Climate Control System - General Information 412-00-54

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
I13: CHECK THE CENTRAL JUNCTION BOX
1 Measure the resistance between the heater
blower relay, socket C920, pin 3, wiring har-
ness side and fuse F76.

• Is a resistance of less than 2 Ohms registered?

→ Yes
RENEW the heater blower relay. CHECK
operation of the system.
→ No
LOCATE and RECTIFY the open circuit be-
tween the heater blower relay and fuse F76
in the central junction box with the aid of the
Wiring Diagrams; if necessary RENEW the
central junction box. CHECK operation of
the system.
I14: CHECK THE VOLTAGE AT THE EATC MODULE
1 Key in OFF position.
2 Disconnect EATC module C539b.
3 Measure the voltage between the EATC mod-
ule, connector C539b, pin 1, circuit 29-FA43
(OG/WH), wiring harness side and ground.

• Is battery voltage measured?

→ Yes
GO to I15
→ No
LOCATE and RECTIFY the open circuit be-
tween fuse F65 and the EATC module with
the aid of the Wiring Diagrams. CHECK op-
eration of the system.

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412-00-55 Climate Control System - General Information 412-00-55

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
I15: CHECK THE VOLTAGE AT THE EATC MODULE
1 Key in ON position.
2 Measure the voltage between the EATC mod-
ule, connector C539b, pin 14, circuit 15S-FA43
(GN/WH), wiring harness side and ground.

• Is battery voltage measured?

→ Yes
GO to I16
→ No
LOCATE and RECTIFY the open circuit be-
tween fuse F76 and the EATC module with
the aid of the Wiring Diagrams. CHECK op-
eration of the system.
I16: CHECK THE GROUND CONNECTION OF THE EATC MODULE
1 Key in OFF position.
2 Measure the resistance between the EATC
module, connector C539b, pin 15, circuit 31-
FA43 (BK), wiring harness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
CHECK and if necessary RENEW the EATC
module. CHECK operation of the system.
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the EATC module and ground
connection G204 with the aid of the Wiring
Diagrams. CHECK operation of the system.

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412-00-56 Climate Control System - General Information 412-00-56

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST J: MALFUNCTION OF THE HEATER BLOWER (VEHICLES WITH EATC ONLY,
DISPLAY ON CLIMATE CONTROL ASSEMBLY OK)
CONDITIONS DETAILS/RESULTS/ACTIONS
J1: CHECK THE VOLTAGE AT THE HEATER BLOWER CONTROL MODULE
1 Key in OFF position.
2 Disconnect heater blower control module
C537.
3 Key in ON position.
4 Measure the voltage between the heater
blower control module, connector C537, pin 2
(right-hand drive vehicles: pin 1), circuit 15S-
FA45 (GN/RD), wiring harness side and
ground.

• Is battery voltage measured?

→ Yes
GO to J2
→ No
LOCATE and RECTIFY the open circuit be-
tween the heater blower control module and
the heater blower relay with the aid of the
Wiring Diagrams. CHECK operation of the
system.
J2: CHECK THE GROUND CONNECTION OF THE HEATER BLOWER CONTROL MODULE
1 Key in OFF position.
2 Measure the resistance between the heater
blower control module, connector C537, pin 1
(right-hand drive vehicles: Pin 2), circuit 31-
FA45 (BK), wiring harness side and ground.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to J3
→ No

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412-00-57 Climate Control System - General Information 412-00-57

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the open circuit in
31-FA45 (BK) between the heater blower
control module and ground connection
G204 with the aid of the Wiring Diagrams.
CHECK operation of the system.
J3: CHECK THE CIRCUITS BETWEEN THE HEATER BLOWER CONTROL MODULE AND THE
EATC MODULE FOR OPEN CIRCUIT
1 Disconnect EATC module C539a.
2 Measure the resistance between the heater
blower control module, connector C537, pin 3
(right-hand drive vehicles: pin 5), circuit 9-FA45
(BN/BU), wiring harness side and the EATC
module, connector C539a, pin 1, circuit 9-FA45
(BN/BU), wiring harness side.

3 Measure the resistance between the heater

blower control module, connector C537, pin 6
(right-hand drive vehicles: pin 4), circuit 49S-
FA45 (BU/WH), wiring harness side and the
EATC module, connector C539a, pin 3, circuit
49S-FA45 (BU/WH), wiring harness side.

• Is a resistance of less than 2 Ohms measured

in both cases?
→ Yes
GO to J4
→ No
LOCATE and RECTIFY the open circuit in
9-FA45 (BN/BU) or 49S-FA45 (BU/WH) be-
tween the heater blower control module and
the EATC module with the aid of the Wiring
Diagrams. CHECK operation of the system.
J4: CHECK THE CIRCUITS BETWEEN THE EATC MODULE AND THE HEATER BLOWER
CONTROL MODULE FOR SHORT TO VOLTAGE
1 Key in ON position.

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412-00-58 Climate Control System - General Information 412-00-58

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the EATC mod-
ule, connector C539a, pin 1, circuit 9-FA45
(BN/BU), wiring harness side and ground.

3 Measure the voltage between the EATC mod-

ule, connector C539a, pin 3, circuit 49S-FA45
(BU/WH), wiring harness side and ground.
• Is a voltage measured during any of these
measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
in circuit 9-FA45 (BN/BU) or 49S-FA45
(BU/WH) between the EATC module and
the heater blower control module with the
aid of the Wiring Diagrams. CHECK opera-
tion of the system.
→ No
GO to J5
J5: CHECK THE CIRCUITS BETWEEN THE EATC MODULE AND THE HEATER BLOWER
CONTROL MODULE FOR SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the EATC
module, connector C539a, pin 1, circuit 9-FA45
(BN/BU), wiring harness side and ground.

3 Measure the resistance between the EATC

module, connector C539a, pin 3, circuit 49S-
FA45 (BU/WH), wiring harness side and
ground.
• Is a resistance greater than 10 kOhm meas-
ured in both cases?
→ Yes

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412-00-59 Climate Control System - General Information 412-00-59

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to J6
→ No
LOCATE and RECTIFY the short to ground
in circuit 9-FA45 (BN/BU) or 49S-FA45
(BU/WH) between the EATC module and
the heater blower control module with the
aid of the Wiring Diagrams. CHECK opera-
tion of the system.
J6: CHECK THE HEATER BLOWER CONTROL MODULE
1 Connect heater blower control module C537.
2 Key in ON position.
• Is the heater blower motor running at approxi-
mately 50 % power?
→ Yes
CHECK and if necessary RENEW the EATC
module. CHECK operation of the system.
→ No
Renew the heater blower control module
CHECK operation of the system.
PINPOINT TEST K: FAULT IN THE CIRCUIT OF THE SUN LOAD SENSOR (VEHICLES WITH
EATC SYSTEM ONLY)
CONDITIONS DETAILS/RESULTS/ACTIONS
K1: CHECK FOR OPEN CIRCUIT BETWEEN THE SUN LOAD SENSOR AND THE EATC MODULE
1 Key in OFF position.
2 Disconnect EATC module C539a.
3 Disconnect EATC module C539b.
4 Disconnect sun load sensor C524.
5 Measure the resistance between the sun load
sensor, connector C524, pin 1, circuit 9-FA53
(BN/BU), wiring harness side and the EATC
module, connector C539a, pin 16, circuit 9-
FA48A (BN/GN), wiring harness side.

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412-00-60 Climate Control System - General Information 412-00-60

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Measure the resistance between the sun load
sensor, connector C524, pin 2, circuit 8-FA53
(WH/BU), wiring harness side and the EATC
module, connector C539b, pin 18, circuit 8-
FA53 (WH/BU), wiring harness side.

• Is a resistance of less than 2 Ohms measured

in both cases?
→ Yes
GO to K2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit between the sun load sensor
and the EATC module with the aid of the
Wiring Diagrams. CHECK operation of the
system.
K2: CHECK THE CIRCUIT BETWEEN THE SUN LOAD SENSOR AND THE EATC MODULE FOR
SHORT TO VOLTAGE SUPPLY
1 Key in ON position.
2 Measure the voltage between the sun load
sensor, connector C524, pin 1, circuit 9-FA53
(BN/BU), wiring harness side and ground.

3 Measure the voltage between the sun load

sensor, connector C524, pin 2, circuit 8-FA53
(WH/BU), wiring harness side and ground.
• Is a voltage measured during any of these
measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
in the affected circuit between the sun load
sensor and the EATC module with the aid of
the Wiring Diagrams. CHECK operation of
the system.
→ No
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412-00-61 Climate Control System - General Information 412-00-61

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to K3
K3: CHECK THE CIRCUIT BETWEEN THE SUN LOAD SENSOR AND THE EATC MODULE FOR
SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the sun load
sensor, connector C524, pin 1, circuit 9-FA53
(BN/BU), wiring harness side and ground.

3 Measure the resistance between the sun load

sensor, connector C524, pin 2, circuit 8-FA53
(WH/BU), wiring harness side and ground.
• Is a resistance greater than 10 kOhm meas-
ured in both cases?
→ Yes
RENEW the sun load sensor. CHECK op-
eration of the system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit between the sun load
sensor and the EATC module with the aid of
the Wiring Diagrams. CHECK operation of
the system.
PINPOINT TEST L: FAULT IN THE CIRCUIT OF THE INTERIOR TEMPERATURE SENSOR
(VEHICLES WITH EATC SYSTEM ONLY)
CONDITIONS DETAILS/RESULTS/ACTIONS
L1: CHECK FOR OPEN CIRCUIT BETWEEN THE INTERIOR TEMPERATURE SENSOR AND THE
EATC MODULE
1 Key in OFF position.
2 Disconnect EATC module C539a.
3 Disconnect EATC module C539b.
4 Disconnect interior temperature sensor C455.

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412-00-62 Climate Control System - General Information 412-00-62

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the resistance between the interior
temperature sensor, connector C455, pin 1,
circuit 8-FA48 (WH/GN), wiring harness side
and the EATC module, connector C539b, pin
16, circuit 8-FA48 (WH/GN), wiring harness
side.

6 Measure the resistance between the interior

temperature sensor, connector C455, pin 2,
circuit 9-FA48 (BN/GN), wiring harness side
and the EATC module, connector C539a, pin
16, circuit 9-FA48A (BN/GN), wiring harness
side.

• Is a resistance of less than 2 Ohms measured

in both cases?
→ Yes
GO to L2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit between the internal tempera-
ture sensor and the EATC module or sol-
dered connection S180 with the aid of the
Wiring Diagrams. CHECK operation of the
system.
L2: CHECK THE CIRCUIT BETWEEN THE INTERIOR TEMPERATURE SENSOR AND THE EATC
MODULE FOR SHORT TO VOLTAGE SUPPLY
1 Key in ON position.

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412-00-63 Climate Control System - General Information 412-00-63

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the interior tem-
perature sensor, connector C455, pin 1, circuit
8-FA48 (WH/GN), wiring harness side and
ground.

3 Measure the voltage between the interior tem-

perature sensor, connector C455, pin 2, circuit
9-FA48 (BN/GN), wiring harness side and
ground.
• Is a voltage measured during any of these
measurements?
→ Yes
LOCATE and RECTIFY the short to voltage
in the affected circuit between the interior
temperature sensor and the EATC module
with the aid of the Wiring Diagrams. CHECK
operation of the system.
→ No
GO to L3
L3: CHECK THE CIRCUIT BETWEEN THE INTERIOR TEMPERATURE SENSOR AND THE EATC
MODULE FOR SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the interior
temperature sensor, connector C455, pin 1,
circuit 8-FA48 (WH/GN), wiring harness side
and ground.

3 Measure the resistance between the interior

temperature sensor, connector C455, pin 2,
circuit 9-FA48 (BN/GN), wiring harness side
and ground.
• Is a resistance greater than 10 kOhm meas-
ured in both cases?
→ Yes

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412-00-64 Climate Control System - General Information 412-00-64

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
RENEW the interior temperature sensor.
CHECK operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit between the interior
temperature sensor and the EATC module
with the aid of the Wiring Diagrams. CHECK
operation of the system.
PINPOINT TEST M: FAULT IN THE CIRCUIT OF THE INTERIOR TEMPERATURE SENSOR
BLOWER (VEHICLES WITH EATC SYSTEM ONLY)
CONDITIONS DETAILS/RESULTS/ACTIONS
M1: CHECK FUSE F81
1 Key in OFF position.
2 CHECK fuse F81 (CJB).
• Is the fuse OK?
→ Yes
GO to M2
→ No
RENEW fuse F81 (7.5 A). CHECK operation
of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
using the Wiring Diagrams.
M2: CHECK VOLTAGE AT FUSE F81
1 Connect fuse F81 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F81 (7.5 A)
and ground.
• Is battery voltage measured?
→ Yes
GO to M3
→ No
RECTIFY the voltage supply to fuse F81
with the aid of the Wiring Diagrams. CHECK
operation of the system.
M3: CHECK THE VOLTAGE AT THE INTERIOR TEMPERATURE SENSOR
1 Key in OFF position.
2 Disconnect interior temperature sensor C455.
3 Key in ON position.

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412-00-65 Climate Control System - General Information 412-00-65

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the interior tem-
perature sensor, connector C455, pin 3, circuit
15S-FA48 (GN/BK), wiring harness side and
ground.

• Is battery voltage measured?

→ Yes
GO to M4
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F81 and the interior tem-
perature sensor with the aid of the Wiring
Diagrams. CHECK operation of the system.
M4: CHECK FOR OPEN CIRCUIT BETWEEN THE INTERIOR TEMPERATURE SENSOR AND THE
EATC MODULE
1 Key in OFF position.
2 Disconnect EATC module C539b.
3 Measure the resistance between the interior
temperature sensor, connector C455, pin 4,
circuit 31S-FA48 (BK/GN), wiring harness side
and the EATC module, connector C539b, pin
2, circuit 31S-FA48 (BK/GN), wiring harness
side.

• Is a resistance of less than 2 Ohms registered?

→ Yes
GO to M5
→ No
LOCATE and RECTIFY the open circuit in
circuit 31S-FA48 (BK/GN) between the inte-
rior temperature sensor and the EATC
module with the aid of the Wiring Diagrams.
CHECK operation of the system.
M5: CHECK THE CIRCUIT BETWEEN THE INTERIOR TEMPERATURE SENSOR AND THE EATC
MODULE FOR SHORT TO VOLTAGE SUPPLY
1 Key in ON position.

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412-00-66 Climate Control System - General Information 412-00-66

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the interior tem-
perature sensor, connector C455, pin 4, circuit
31S-FA48 (BK/GN), wiring harness side and
ground.

• Is a voltage registered?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in circuit 31S-FA48 (BK/GN) be-
tween the interior temperature sensor and
the EATC module with the aid of the Wiring
Diagrams. CHECK operation of the system.
→ No
GO to M6
M6: CHECK THE CIRCUIT BETWEEN THE INTERIOR TEMPERATURE SENSOR AND THE EATC
MODULE FOR SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the interior
temperature sensor, connector C455, pin 4,
circuit 31S-FA48 (BK/GN), wiring harness side
and ground.

• Is a resistance of more than 10 kOhms regis-

tered?
→ Yes
RENEW the interior temperature sensor.
CHECK operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in circuit 31S-FA48 (BK/GN) between the in-
terior temperature sensor and the EATC
module with the aid of the Wiring Diagrams.
CHECK operation of the system.

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412-00-67 Climate Control System - General Information 412-00-67

DIAGNOSIS AND TESTING

Testing the Refrigerant Circuit

Component Tests
Workshop Equipment
The following equipment is required for the tests:
Air conditioning wide open throttle (WOT) relay.
• R134a refrigerant centre or set of R134a
1. Check the normally open contact in the pressure gauges
unswitched state.
• Measure the resistance at the relay, • Stopwatch
between pin 3 and pin 5, component side.
• Is a resistance of more than 10 kOhms Pinpoint Test: Refrigerant Circuit
registered? If yes, go to 2. If no, RENEW
the relay. WARNING: The air conditioning systems
is filled with refrigerant R134a. Observe
"Health and Safety Precautions". For
further information REFER to Section
100-00.
NOTE: The following Pinpoint Test only applies
to vehicles with compressors without low-
pressure circuit control (vehicles with 2.0L diesel
engine only).
The following values must be determined:
• Low pressure
• High pressure
• Cycle time
Test Preparations
2. Check the normally open contact in the
switched state. The following steps must be carefully followed to
• Using a fused test cable (1 A), connect pin guarantee accurate test results.
1 of the relay, component side, to the
WARNING: The manufacturer's
battery positive terminal.
instructions must be followed when
• Using a test cable, connect pin 2 of the connecting the R-134a refrigerant centre
relay, component side, to the battery or the set of R134a pressure gauges.
negative terminal. Failure to observe this instruction can
• Measure the resistance at the relay, lead to injuries.
between pin 3 and pin 5, component side. • Connect the R134a refrigerant centre or set
• Is a resistance of less than 2 Ohms of R134a pressure gauges to the refrigerant
registered? If yes, then the relay is OK. If circuit.
no, RENEW the relay. • Start the engine.
• Switch on the air-conditioning system.
• Switch on the air recirculation.
• Set the heater blower switch to "maximum".
• Run the engine for approx. 10 minutes at
1500 rpm.
Check the cycle time and system pressures
Allow the engine to run at 1500 rpm during the
test.

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412-00-68 Climate Control System - General Information 412-00-68

DIAGNOSIS AND TESTING (Continued)

1. Set the interior temperature in the vehicle to Low pressure
approx. 22 °C.
2. Measure the cycles (ON and OFF times of
the A/C compressor clutch) with a stopwatch
and note the results.
3. Take readings from the high and low
pressure gauge and note the values.
4. Compare the obtained cycle times and
pressure values with the following specified
values and use the Symptom Chart to
determine the cause of the fault.
Example:
• High pressure too low
• Low pressure normal Co-ordinate axis Description
• Overall cycle time too short 1 Low pressure (bar)
• "A/C compressor clutch ON" cycle time too 2 Ambient temperature
short (°C)
• "A/C compressor clutch OFF" cycle time too
short
A/C compressor clutch switched on
Fault cause: Refrigerant quantity insufficient.

Specified values (vehicles with 2.0L diesel engine

only)
The high and low pressure values and the cycle
times are dependent upon the ambient
temperature. The ambient temperature should be
measured at a distance of 1 m from the vehicle.
The applicable tolerance range which describes
the "normal" range for a measured value, lies
between the upper and lower curves.

High pressure Co-ordinate axis Description

1 A/C compressor clutch
switched on (seconds)
2 Ambient temperature
(°C)

Co-ordinate axis Description

1 High pressure (bar)
2 Ambient temperature
(°C)

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412-00-69 Climate Control System - General Information 412-00-69

DIAGNOSIS AND TESTING (Continued)

A/C compressor clutch switched off

Co-ordinate axis Description

Co-ordinate axis Description 1 Total cycle time (sec-
1 A/C compressor clutch onds)
switched off (seconds) 2 Ambient temperature
2 Ambient temperature (°C)
(°C)
Symptom Chart: Refrigerant Circuit
Total cycle time
NOTE: The total cycle time is made up of the
"A/C compressor clutch ON time" and the "A/C
compressor clutch OFF time".
"A/C "A/C
High Low Total cycle compressor compressor
Fault cause
pressure pressure time clutch ON" clutch OFF"
cycle time cycle time
Inadequate heat dissipation
continuously at the condenser (e.g. cooling
too high too high too long -
switched on fan inoperative, external con-
tamination of the condenser)
Air, foreign material or too
normal to continuously
normal too long - much refrigerant in the refrig-
too high switched on
erant circuit
continuously Fixed orifice tube O-rings
normal too high too long -
switched on leaking/damaged
Foreign material (e.g. mois-
too long to con- normal to not at
normal normal too long ture) or too much refrigerant
tinuous all
oil in the refrigerant circuit
normal too low too long too long too long Low-pressure switch faulty
normal to continuously
too high too long - A/C compressor faulty
too low switched on
normal to normal to continuously Low pressure line to the A/C
too long -
too low too high switched on compressor blocked
normal to
normal too short too short normal Evaporator blocked
too low
normal to too short to normal to too Condenser, fixed orifice tube
normal too short
too low normal long or high-pressure line blocked
normal to Refrigerant quantity insuffi-
normal too short too short too short
too low cient
normal to High-pressure line to the
normal too short too short too long
too low evaporator blocked
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412-00-70 Climate Control System - General Information 412-00-70

DIAGNOSIS AND TESTING (Continued)

"A/C "A/C
High Low Total cycle compressor compressor
Fault cause
pressure pressure time clutch ON" clutch OFF"
cycle time cycle time
Low pressure line to the A/C
compressor blocked, or a
normal to continuously
too low too long - fault in the control via the low
too low switched on
pressure switch (fails to
switch off).

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412-00-71 Climate Control System - General Information 412-00-71

GENERAL PROCEDURES

Spring Lock Coupling

GENERAL PROCEDURES

1. NOTE: Select special tool to suit the line

diameter.
4. Connect the refrigerant line.
Fit the special tool. • Check the clamping spring for damage.
• Fit the special tool so that the inner collar • Carefully pull out any damaged clamping
can be guided into the clamping spring. springs using a thin piece of wire and in-
stall new one.

2. Press the special tool into the clamping

spring. 5. NOTE: Clean the connections using refrigerant
oil and a lint-free cloth.
Press the indicator ring into the clamping
spring.

3. Disconnect the refrigerant line.

• Discard the O-ring seals.

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412-00-72 Climate Control System - General Information 412-00-72

GENERAL PROCEDURES (Continued)

6. NOTE: Install new refrigerant line O-ring seals.
NOTE: Coat the refrigerant line O-ring seals in
clean refrigerant oil prior to installation.
Connect the refrigerant lines.
• Check that the clamping spring engages
correctly.

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412-00-73 Climate Control System - General Information 412-00-73

GENERAL PROCEDURES

Air Conditioning (A/C) Clutch Air Gap Adjustment (34 628 6)

Name Specification
Spacer washer set
1. Check the air gap A between the drive
plate and the pulley at 60 degrees intervals
around the circumference. For additional
information, refer to Specifications in this
section.
1. Belt pulley
2. Spacer washer
3. Drive plate

2. Detach the drive plate.

3. Correct air gap A as necessary using

spacer washers.
4. Attach the drive plate.
5. Check air gap A as described in step 1.
Repeat steps 3-6 if necessary.

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412-00-74 Climate Control System - General Information 412-00-74

GENERAL PROCEDURES

Air Conditioning (A/C) System Recovery, Evacuation and Charging (34 620 2)
3. NOTE: The air conditioning system has to be
evacuated for approximately 30 minutes in
order to make sure that the system will work
General Equipment perfectly again once refilled.
Service unit NOTE: If moisture has entered the open system
over an extended period of time (several hours),
1. WARNING: Observe "Health and Safety install a new accumulator/dryer and extend the
Rules". For additional information, evacuation time to 2-3 hours.
refer to Section 100-00. Evacuate the air conditioning system in
CAUTION: The refrigerant detector must accordance with the service unit
be used before evacuation; otherwise, manufacturer instructions.
the service unit may become 4. NOTE: If an air conditioning system is
contaminated. Contaminated refrigerant evacuated before the refrigerant has been
must be disposed of as hazardous drained, some of the refrigerant will remain in
waste. Always follow the manufacturer the compressor refrigerant oil. This remaining
instructions when using the service refrigerant may evaporate, causing a slight
units. increase (maximum two marks) in the reading
on the pressure gauge during the leak test.
Remove the protective caps of the filler This increase in pressure does not mean the
valves and connect the service unit leads air conditioning system is leaking.
to the filler valves.
• Pull back the lock on the quick-release Carry out a leak test.
connector. • To test for leaks, close the hand valves on
1. Larger inside diameter for high-pressure the pressure gauge head, switch off the
side. service unit vacuum pump and observe the
low-pressure gauge.
2. Smaller inside diameter for low-pressure
side. • If the reading increases by more than 20
mbar (2 kPa, 0.29 psi), this means that the
system is leaking.
• If the air conditioning system is leaking, fill
it with approximately 300 g refrigerant and
check using a leakage detector. For
additional information, refer to Leak test in
this section.
CAUTION: Always evacuate the air
conditioning system before filling it.
NOTE: Depending on the service unit and
equipment (with or without heatable filler
cylinder), the air conditioning system can be filled
in liquid form through the high-pressure port or in
gaseous form through the low-pressure port.
2. WARNING: Avoid releasing the NOTE: Fill quantity indicated on sticker in engine
refrigerant into the atmosphere at all compartment.
costs.
Drain the air conditioning system through
the low-pressure port in accordance with
the service unit manufacturer instructions.

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412-00-75 Climate Control System - General Information 412-00-75

GENERAL PROCEDURES (Continued)

5. Filling the air conditioning system through

the high-pressure port (liquid fill).
• Open the high-pressure shut-off valve on
the pressure gauge head.
• Switch the service unit to "Fill" mode and
fill the system with the prescribed quantity
of liquid refrigerant (R134a).

6. CAUTION: Filling the air conditioning

system through the low-pressure port
(gas fill only).
Filling the air conditioning system through
the low-pressure port.
• Open the low-pressure shut-off valve on
the pressure gauge head.
• Switch the service unit to "Fill" mode and
fill the system with the prescribed quantity
of gaseous refrigerant.
• Top up with the remaining refrigerant whilst
the air conditioning is switched on. Let the
engine run at about 1200-1500 rpm for this
purpose. Switch the air conditioning to
maximum cooling power and fresh air
mode. Set the blower to maximum power.
Allow the remainder of the prescribed
amount to be drawn in.
7. NOTE: Do not detach the high-pressure hose
whilst the air conditioning is switched on.
Disconnect the service unit.
• Close the shut-off valves.
• Switch off the service unit.
• Disconnect the refrigerant hoses from the
air conditioning system.
• Screw the protective caps onto the filler
valves.

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412-00-76 Climate Control System - General Information 412-00-76

GENERAL PROCEDURES

Refrigerant Oil Adding (34 621 1)

CAUTION: Store the refrigerant oil in a

closed, sealed container to prevent the
ingress of moisture.
NOTE: Collect the refrigerant oil in a clean
measuring cylinder when replacing the A/C
compressor, the dehydrator or refrigerant lines.
1. NOTE: This step only needs to be carried out
when removing the A/C compressor.
Drain the refrigerant oil from the A/C
compressor.
• Rotate the compressor shaft at least 6 to 8
turns when draining the refrigerant oil.
2. NOTE: This step only needs to be carried out
when removing the dehydrator.
Drain the refrigerant oil from the
dehydrator.
3. NOTE: This step only needs to be carried out
when removing refrigerant lines.
Drain the refrigerant oil from the
refrigerant lines.
4. NOTE: If more than one air conditioning
system component is being renewed, the oil
quantity to be added is the sum of each
individual quantity.
NOTE: In addition, add the same quantity of new
refrigerant oil as was collected in the oil
separator of the servicing unit when the air
conditioning was drained.
Add the calculated quantity of new
refrigerant oil. For additional information,
refer to General Specifications in this
section.

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412-00-77 Climate Control System - General Information 412-00-77

GENERAL PROCEDURES

Electronic Leak Detection (34 620 7)

1. CAUTION: The refrigerant identification
equipment must be used before the
Special Tool(s) manifold gauge set is installed,
otherwise the manifold gauge may
Automatic Calibration become contaminated. Contaminated
Halogen Leak Detector or refrigerant must be disposed of as
equivalent special waste. The manufacturer's
instructions must be followed when
working with the service unit.
NOTE: Both manifold gauges should indicate
R-134a Manifold Gauge Set 4,1-5,5 bar at 24°C with the engine off.
or equivalent Attach the manifold gauge set to the
service gauge port valves.
1. For the leak test, close the manual valves
on the gauge set.
Refrigerant identifier or 2. If little or no pressure is indicated, charge
equivalent the system with approx. 300g of refrigerant.
2. Use R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant
system. Follow the instructions included
with leak detector for handling and
operation techniques.
WARNING: Good ventilation before leak 3. If a leak is found, recover the A/C system.
detection is necessary in the area where
it is to be performed. If the surrounding
air is contaminated with refrigerant gas,
the leak detector will indicate this gas all
the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can
cause the same problem. While leak
detection air movement must be
prevented.

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412-00-78 Climate Control System - General Information 412-00-78

GENERAL PROCEDURES

Flourescent Dye Leak Detection

Special Tool(s)
120 Watt UV Spot Lamp or
equivalent

R-134a Manifold Gauge Set

or equivalent

R-134a Fluorescent Dye

Injector

NOTE: Vehicles built 07/1999 onwards have a

fluorescent tracer dye tablet inserted into the air
conditioning (A/C) system. If tracer dye is
present, there is a green cross on the suction
accumulator.
NOTE: On vehicles built up to 07/1999 tracer dye
must be added.
1. Using the dye injector, add 7.4 ml of
Fluorescent Tracer Dye.
NOTE: Some vehicles may have signs of
refrigerant oil at the spring lock couplers. This
may be caused from the assembly process which
applies to the fittings before installation to aid in
assembly. When a spring lock coupler is
suspected of leaking, always wipe the fitting
clean and verify the leak with R-134a Automatic
Calibration Halogen Leak Detector.
NOTE: The exact location of leaks can be
pinpointed by the bright yellow - green glow of
the tracer dye. Since more than one leak may
exist, always inspect each component.
2. Check for leaks using a 120 Watt UV Spot
Lamp. Always scan all components,
fittings and lines of the A/C system.
3. After the leak is found and repaired,
remove any traces of dye with a general
purpose oil solvent.
4. Verify the repair by operating the system
for some minutes and inspecting with the
UV lamp again.

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412-00-79 Climate Control System - General Information 412-00-79

GENERAL PROCEDURES

Vacuum Leak Detection (34 620 3)

1. Drain the air conditioning (A/C) system.

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412-00-80 Climate Control System - General Information 412-00-80

GENERAL PROCEDURES

Contaminated Refrigerant Handling (34 620 9)

CAUTION: Any R134a or R12 refrigerant

which is contaminated with unsuitable
refrigerant should be extracted only by
means of a suitable servicing unit
designed for the purpose of collecting
and storing contaminated refrigerant, so
that the spread to other vehicles can be
prevented.
1. Use refrigerant identification equipment to
check that there is contaminated
refrigerant in the air conditioning system.
2. Inform the customer about the additional
cost to repairing the system caused by
the contamination.
3. Extract the contaminated refrigerant.

G18273 en 08/2002 2003.0 Mondeo

412-01-1 Air Distribution and Filtering 412-01-1

SECTION 412-01 Air Distribution and Filtering

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Air Distribution and Filtering............................................................................................... 412-01-2

DIAGNOSIS AND TESTING

Air Distribution and Filtering............................................................................................... 412-01-3

REMOVAL AND INSTALLATION

Pollen Filter .................................................................................................. (34 350 0) 412-01-4

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412-01-2 Air Distribution and Filtering 412-01-2

DESCRIPTION AND OPERATION

Air Distribution and Filtering

DESCRIPTION AND OPERATION

The purpose of the air distribution system is to

route air to the designated registers. This is
accomplished when air enters the plenum
through the fresh air inlet and is routed to the
selected outlets by use of distribution doors.
The incoming fresh air is passed through a pollen
filter which is standard and is located under the
air cowl trim panel on the front passengers side.
There are two different filter elements available:
– The standard pollen filter is capable of
removing all airborne particles larger than
three microns in size and cleans the air of
pollen, dusts and diesel soot.
– The activated carbon combination filter is
optional and has the same advantages as the
pollen filter plus an effective active carbon
layer, which neutralizes unpleasant adours
and keeps the air free of ozone.
Air ducts route air to specific areas of the air
distribution system. These areas are the floor
ducts, panel registers, side window demisters
and defrost nozzles.
The instrument panel registers are adjustable
and used to aim the discharged air to a required
area. The floor ducts, side window demisters and
defrost nozzles are nonadjustable.

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412-01-3 Air Distribution and Filtering 412-01-3

DIAGNOSIS AND TESTING

Air Distribution and Filtering

DIAGNOSIS AND TESTING

REFER to Section 412-00.

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412-01-4 Air Distribution and Filtering 412-01-4

REMOVAL AND INSTALLATION

Pollen Filter (34 350 0)

REMOVAL AND INSTALLATION

Removal 3. Remove the pollen filter housing cover.

1. NOTE: Make sure that the windshield wiper • Detach the retaining straps on both sides.
motor is in the park position.
Remove the windshield wiper arms.

4. Remove the pollen filter.

2. Remove the cowl panels. Installation

• Pull the cowl panels out of the retaining
groove. 1. To install, reverse the removal procedure.

G37699 en 08/2002 2003.0 Mondeo

412-02A-1 Heating and Ventilation 412-02A-1

SECTION 412-02A Heating and Ventilation

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 412-02-2

DESCRIPTION AND OPERATION

Heating and Ventilation...................................................................................................... 412-02-3

Heater Core Housing........................................................................................................ 412-02-3

DIAGNOSIS AND TESTING

Heating and Ventilation...................................................................................................... 412-02-4

REMOVAL AND INSTALLATION

Blower Motor ................................................................................................ (34 374 0) 412-02-5

Heater Core and Evaporator Core Housing ....................................................................... 412-02-7
Heater Core.................................................................................................. (34 364 0) 412-02-12

DISASSEMBLY AND ASSEMBLY

Heater Core and Evaporator Core Housing ....................................................................... 412-02-14

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412-02A-2 Heating and Ventilation 412-02A-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
In-vehicle crossbeam retaining bolts 20 15 -

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412-02A-3 Heating and Ventilation 412-02A-3

DESCRIPTION AND OPERATION

Heating and Ventilation

DESCRIPTION AND OPERATION

floor, instrument panel or defrost nozzles, as

required. For additional information, refer to
The heating and ventilation system is a blended Section 412-01.
air system and consists of a heater core, a
blower motor, distribution doors and an
evaporator core on vehicles equipped with air Heater Core Housing
conditioning (A/C).
In the heater core housing, all blend doors are
Air is directed through the heater core for heating actuated electronically by means of control
and around for cooling, mixed and discharged motors.
through outlets in the plenum assembly to the

Item Description
1 Defrost vent blend door actuator
2 Outlet air temperature sensor
3 Air inlet blend door actuator
4 Blower motor
5 Blower motor resistor
6 Temperature blend door actuator
7 Center vent/footwell vent blend door actuator

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412-02A-4 Heating and Ventilation 412-02A-4

DIAGNOSIS AND TESTING

Heating and Ventilation

DIAGNOSIS AND TESTING

REFER to Section 412-00.

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412-02A-5 Heating and Ventilation 412-02A-5

REMOVAL AND INSTALLATION

Blower Motor (34 374 0)

REMOVAL AND INSTALLATION

Removal 3. Remove the glove compartment.

1. Remove the footwell lower trim panel (five 1. Press the sides towards the center to
clips). release the glove compartment.
2. Pull the glove compartment out of the
hinges.

2. Detach the damper from the glove

compartment.
1. Open the glove compartment to access the 4. Disconnect the blower motor electrical
damper. connector.
2. Push the top of the damper away from the
glove compartment.

5. Remove the blower motor.

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412-02A-6 Heating and Ventilation 412-02A-6

REMOVAL AND INSTALLATION (Continued)

Installation
1. To install, reverse the removal procedure.

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412-02A-7 Heating and Ventilation 412-02A-7

REMOVAL AND INSTALLATION

Heater Core and Evaporator Core Housing

All vehicles
5. Using the special tool, disconnect the
coolant hoses from the heater core.
Special Tool(s)
• Disconnect the water drain hose from the
Disconnect Tool, Spring Lock water drain channel.
Coupling 1/2 inch (blue)
412-027 (34-001)

Disconnect Tool, Spring Lock

Coupling 5/8 inch (black)
412-081 (34-003)

Remover/Installer, Cooling
Hose Clamp
303-397 (24-003)
6. Lower the vehicle.
7. Remove the instrument panel. For
additional information, refer to Section
501-12.
Removal
8. Remove the duct.
All vehicles
1. Drain the cooling system. For additional
information, refer to Section 303-03.
2. Drain the air conditioning system. For
additional information, refer to Section
412-00.
3. Raise and support the vehicle. For
additional information, refer to Section
100-02.
Vehicles with diesel engine
4. Remove the engine undershield.

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412-02A-8 Heating and Ventilation 412-02A-8

REMOVAL AND INSTALLATION (Continued)

9. Detach the right-hand door opening 12. Disconnect the main body electrical con-
weatherstrip from the A-pillar. nector.

10. Remove the right-hand cowl side trim 13. Disconnect the generic electronic module
panel. (GEM) electrical connectors.

11. Remove the ground connection retaining 14. Detach the wiring harness from the
bolts. heater core and evaporator core housing.

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412-02A-9 Heating and Ventilation 412-02A-9

REMOVAL AND INSTALLATION (Continued)

15. Disconnect the vent actuators electrical 18. Disconnect the parking brake warning
connectors. light switch electrical connector.
• Unclip the wiring harness.

19. Disconnect the adaptive restraint module

16. Disconnect the blower motor and blower electrical connectors.
motor resistor electrical connectors. • Unclip the wiring harness.

17. Disconnect the temperature sensor elec- 20. Disconnect the central junction box (CJB)
trical connector. electrical connectors.

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412-02A-10 Heating and Ventilation 412-02A-10

REMOVAL AND INSTALLATION (Continued)

All vehicles
21. Remove the windshield air duct.
24. Remove the refrigerant line spring lock
coupling locking clips.

Vehicles built up to 05/2001

22. Remove the in-vehicle crossbeam
retaining bolts (right-hand side shown). CAUTION: Cap the refrigerant lines and
• Remove the blanking caps. the evaporator core to prevent dirt
ingress.
25. Using the special tool, disconnect the
left-hand refrigerant line from the
evaporator core.
• Discard the O-ring seals.

Vehicles with 2.5L engine

23. Remove the ignition coil. For additional
information, refer to Section 303-07A /
303-07B.

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412-02A-11 Heating and Ventilation 412-02A-11

REMOVAL AND INSTALLATION (Continued)

26. Using the special tool, disconnect the 29. Remove the heater core and evaporator
right-hand refrigerant line from the core housing.
evaporator core.
• Discard the O-ring seals.

Installation
27. Remove the heater core and evaporator
core housing retaining nut. 1. NOTE: Install new refrigerant line O-ring seals.
NOTE: Lubricate the refrigerant line O-ring seals
with clean refrigerant oil before installation.
To install, reverse the removal procedure.

28. Remove the in-vehicle crossbeam.

• Unclip the wiring harness.

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412-02A-12 Heating and Ventilation 412-02A-12

REMOVAL AND INSTALLATION

Heater Core (34 364 0)

5. Lower the vehicle.

Special Tool(s) 6. Remove the right and left-hand centre
console side trim panel (left-hand side
Remover/Installer, Coolant shown).
Hose Clamp
1. Remove the bolt.
303-397 (24-003)
2. Release the clips and remove the centre
console side trim panel.

Removal
All vehicles
1. Drain the cooling system.For additional
information, refer to Section 303-03.
2. Raise the vehicle.For additional
information, refer to Section 100-02.
Vehicles with diesel engine
3. Detach engine undershield.

7. Disconnect the rear footwell air guide from

the heater core housing (shown with
heater core / evaporator housing removed
for clarity).

All vehicles
4. Using the special tool, detach the coolant
hoses from the heater core.
• Disconnect the water drain hose from the
water drain connection.

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412-02A-13 Heating and Ventilation 412-02A-13

REMOVAL AND INSTALLATION (Continued)

8. Remove the rear footwell air guide. 11. Remove the heater core screw.
1. Remove the air guide screw.
2. Push the air guide upwards.
3. Release the retainers.

12. Remove the heater core.

9. Remove the heater core housing (shown

with heater core and evaporator housing
removed for clarity).
1. Remove the clips.
2. Release the retainers.

Installation
1. Install the components in the reverse
order.

10. Remove the rubber seal.

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412-02A-14 Heating and Ventilation 412-02A-14

DISASSEMBLY AND ASSEMBLY

Heater Core and Evaporator Core Housing

DISASSEMBLY AND ASSEMBLY

Disassembly 4. Remove the rubber seal.

1. Remove the blend door actuator assembly.

5. Remove the heater core retaining bolt.

2. Remove the air inlet blend door actuator.

6. Remove the heater core.

3. Remove the heater core housing.
1. Remove the retaining clips.
2. Release the retaining tabs.

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412-02A-15 Heating and Ventilation 412-02A-15

DISASSEMBLY AND ASSEMBLY (Continued)

7. Detach the evaporator core upper housing. 10. Remove the evaporator core uppper
housing.

8. Remove the rubber seal.

11. Remove the evaporator core.

9. Remove the evaporator core retaining bolt.

12. Remove the blower motor.

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412-02A-16 Heating and Ventilation 412-02A-16

DISASSEMBLY AND ASSEMBLY (Continued)

13. Remove the blower motor resistor. 16. Separate the evaporator core housing.
1. Remove the retaining clip.
2. Release the retaining tabs.

14. Remove the blower motor upper housing.

1. Remove the two retaining clips.
2. Release the eight retaining tabs. 17. Separate the heater core and evaporator
core housing.
1. Pull off the retaining clip.
2. Release the five retaining tabs.

15. Separate the blower motor upper

housing.
1. Remove the gasket.
2. Release the retaining tabs. 18. Remove the blend doors.
1. Pull out the three blend doors.
2. Pull out the three blend door shafts.

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412-02A-17 Heating and Ventilation 412-02A-17

DISASSEMBLY AND ASSEMBLY (Continued)

Assembly
1. To assemble, reverse the disassemble
procedure.

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412-02B-1 Auxiliary Heating 412-02B-1

SECTION 412-02B Auxiliary Heating

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 412-02-2

DESCRIPTION AND OPERATION

Electric Booster Heater...................................................................................................... 412-02-3

DIAGNOSIS AND TESTING

Electric Booster Heater...................................................................................................... 412-02-4

Inspection and Verification ............................................................................................... 412-02-4
Symptom chart ................................................................................................................. 412-02-4
Pinpoint Test .................................................................................................................... 412-02-4
Component Tests ............................................................................................................. 412-02-14

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412-02B-2 Auxiliary Heating 412-02B-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Engine undershield retaining bolts 10 – 89
Booster heater exhaust pipe retaining bolts 10 – 89
Booster heater bracket retaining nuts 7 – 62
Booster heater retaining bolts 10 – 68
Air intake hose retaining bolt 5 – 44

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412-02B-3 Auxiliary Heating 412-02B-3

DESCRIPTION AND OPERATION

Electric Booster Heater

DESCRIPTION AND OPERATION

In some markets an electrically powered booster

heater is installed to improve the heating output
of the highly efficient diesel engines.
The booster heater is switched on by the
powertrain control module (PCM) at an intake air
temperature of approximately 0°C.
The cooling system is heated with three glow
plugs which are actuated by the PCM when the
engine is running.
NOTE: Do not change the glow plugs separately
to prevent of any coolant leaks.
The glow plugs are located together in a separate
housing in the coolant circuit.
The heating output of the glow plugs is 750 W.
Item Description
1 Glow plugs

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412-02B-4 Auxiliary Heating 412-02B-4

DIAGNOSIS AND TESTING

Electric Booster Heater

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 412-02B for 3. RESOLVE any obvious causes for a concern
schematic and connector information. found during the visual inspection before
carrying out any further tests. CHECK
operation of system
Inspection and Verification
4. If the concern persists after the visual
1. Check customer concern. inspection, use WDS to PERFORM a fault
2. Visually CHECK for any obvious mechanical diagnosis of the electronic engine
or electrical damage. management (PCM) and RESOLVE the
fault(s) displayed according to the fault
Visual inspection description. CHECK system operates
correctly
Mechanical Electrical
5. If no fault code is stored, CONTINUE with the
• Coolant level • Fuses Symptom Chart.
• Auxiliary heater • Wiring harness
mounting • Connector(s)
Symptom chart

Condition Possible Sources Action

• Coolant additional electric • Fuse(s) • GO to Pinpoint Test A
heater inoperative / partly inop- • Circuit(s)
erative • Intake air temperature signal
• Relay 1, coolant additional
electric heating
• Relay 2, coolant additional
electric heating
• Coolant additional electric
heater
• Powertrain control module
(PCM)

Pinpoint Test
PINPOINT TEST A: COOLANT ADDITIONAL ELECTRIC HEATER INOPERATIVE / PARTLY
INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
1 Check the operation of the coolant additional
electric heater.
• Are levels 1 and 2 of the coolant additional
electric heater inoperative?
→ Yes
GO to A2
→ No
Only level 1 is inoperative: GO to A10
Only level 2 is inoperative: GO to A16
A2: CHECK FUSE F3
1 Key in OFF position.
2 CHECK Fuse F3 (BJB).

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412-02B-5 Auxiliary Heating 412-02B-5

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is fuse OK?
→ Yes
GO to A3
→ No
RENEW fuse F3 (60 A). If the fuse blows
again, LOCATE and REPAIR the short to
ground using the wiring diagrams. CHECK
the system again
A3: TEST VOLTAGE AT FUSE F3
1 Connect Fuse F3 (BJB).
2 Test voltage between fuse F3 (60 A) and
ground.
• Does the meter display battery voltage?
→ Yes
GO to A4
→ No
REPAIR the voltage supply to fuse F3 with
the aid of the Wiring Diagrams. CHECK op-
eration of system
A4: CHECK FUSE F82
1 CHECK Fuse F82 (CJB).
• Is fuse OK?
→ Yes
GO to A5
→ No
RENEW fuse F82 (7.5 A). If the fuse blows
again, LOCATE and REPAIR the short to
ground using the wiring diagrams. CHECK
the system again
A5: TEST VOLTAGE AT FUSE F82
1 Connect Fuse F82 (CJB).
2 Key in ON position.
3 Test voltage between fuse F82 (7.5 A) and
ground.
• Does the meter display battery voltage?
→ Yes
GO to A6
→ No
REPAIR the voltage supply to fuse F82 with
the aid of the Wiring Diagrams. CHECK op-
eration of system
A6: CHECK VOLTAGE AT RELAY 1, COOLANT ADDITIONAL ELECTRIC HEATING
1 Key in OFF position.
2 Disconnect Relay 1, coolant additional electric
heating C125.

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412-02B-6 Auxiliary Heating 412-02B-6

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between relay 1, coolant
additional electric heating, connector C125, pin
3, circuit 30-RH24A (RD), wiring harness side
and ground.

• Does the meter display battery voltage?

→ Yes
GO to A7
→ No
LOCATE and REPAIR the break in the cir-
cuit between fuse F3 and splice S361 with
the aid of the Wiring Diagrams. CHECK op-
eration of system
A7: CHECK CONTROL VOLTAGE AT RELAY 1, COOLANT ADDITIONAL ELECTRIC HEATING
1 Key in ON position.
2 Measure the voltage between relay 1, coolant
additional electric heating, connector C125, pin
1, circuit 15-RH23 (GN/RD), wiring harness
side and ground.

• Does the meter display battery voltage?

→ Yes
GO to A8
→ No
LOCATE and REPAIR break in circuit be-
tween relay 1, coolant additional electric
heating or relay 2, coolant additional electric
heating and fuse F82 using the wiring dia-
grams. CHECK operation of system
A8: CHECK THE GROUND CONNECTION OF THE COOLANT ADDITIONAL HEATING
1 Key in OFF position.

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412-02B-7 Auxiliary Heating 412-02B-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between relay 1, cool-
ant additional electric heating, connector C125,
pin 5, circuit 15S-RH24 (GN/OG) and ground.

• Is a resistance of less than 0,9 Ohm regis-

tered?
→ Yes
GO to A9
→ No
CHECK the ground connection of the cool-
ant additional electric heater, if necessary
CLEAN the threaded connection(s) on the
bulkhead. CHECK operation of system
A9: TEST THE SIGNAL FROM THE INTAKE AIR TEMPERATURE SENSOR
NOTE: The intake air temperature sensor is integrated in the mass air flow sensor (engine manage-
ment).
1 Connect the diagnostic tool.
2 Key in ON position.
3 Test the intake air temperature signal using the
WDS.
• Is the intake air temperature signal OK? (i.e. is
the shown temperature plausible?)
→ Yes
CHECK the powertrain control module
(PCM) and RENEW as necessary. CHECK
operation of system
→ No
For further information, refer to REFER to
Section 303-14.
A10: CHECK VOLTAGE AT RELAY 1, COOLANT ADDITIONAL ELECTRIC HEATING
1 Key in OFF position.
2 Disconnect Relay 1, coolant additional electric
heating C125.

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412-02B-8 Auxiliary Heating 412-02B-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between relay 1, coolant
additional electric heating, connector C125, pin
3, circuit 30-RH24A (RD), wiring harness side
and ground.

• Does the meter display battery voltage?

→ Yes
GO to A11
→ No
LOCATE and RECTIFY the break in circuit
30-RH24A (RD) between relay 1, coolant
additional electric heating and solder point
S361 using the Wiring Diagrams. CHECK
operation of system
A11: CHECK CONTROL VOLTAGE AT RELAY 1, COOLANT ADDITIONAL ELECTRIC HEATING
1 Key in ON position.
2 Measure the voltage between relay 1, coolant
additional electric heating, connector C125, pin
1, circuit 15-RH23 (GN/RD), wiring harness
side and ground.

• Does the meter display battery voltage?

→ Yes
GO to A12
→ No
LOCATE and RECTIFY the break in circuit
15-RH23 (GN/RD) between relay 1, coolant
additional electric heating and fuse F82 us-
ing the Wiring Diagrams. CHECK operation
of system
A12: CHECK THE CIRCUIT BETWEEN RELAY 1, COOLANT ADDITIONAL ELECTRIC HEATING
AND THE COOLANT ADDITIONAL ELECTRIC HEATER FOR OPEN CIRCUIT.
1 Key in OFF position.

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412-02B-9 Auxiliary Heating 412-02B-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between relay 1, cool-
ant additional electric heating, connector C125,
pin 5, circuit 15S-RH24 (GN/OG), wiring har-
ness side and ground.

• Is a resistance of less than 0,9 Ohm regis-

tered?
→ Yes
GO to A14
→ No
GO to A13
A13: CHECK THE COOLANT ADDITIONAL ELECTRIC HEATER
1 Disconnect Coolant additional electric heating
C124.
2 Measure the resistance between coolant addi-
tional electric heating, connector C124, pin 1,
circuit 15S-RH24 (GN/OG), component side
and ground.

• Is a resistance of less than 0,9 Ohm regis-

tered?
→ Yes
LOCATE and RECTIFY the break in circuit
15S-RH24 (GN/OG) between relay 1, cool-
ant additional electric heating and the cool-
ant additional electric heater using the Wir-
ing Diagrams. CHECK operation of system
→ No
RENEW the coolant additional electric
heater. CHECK operation of system
A14: CHECK RELAY 1, COOLANT ADDITIONAL ELECTRIC HEATING
1 Check relay 1, coolant additional electric heat-
ing in accordance with the component test at
the end of this section.

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412-02B-10 Auxiliary Heating 412-02B-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is relay 1, coolant additional electric heating

OK?
→ Yes
GO to A15
→ No
RENEW relay 1, coolant additional electric
heating CHECK operation of system
A15: CHECK THE CIRCUIT BETWEEN PCM AND RELAY 1, COOLANT ADDITIONAL ELECTRIC
HEATING FOR OPEN CIRCUIT
1 Disconnect PCM C100.
2 Measure resistance between relay 1, coolant
additional electric heating, socket C125, pin 2,
circuit 91S-RH23 (BK/OG), wiring harness side
and PCM, connector C100, pin 98, circuit 91S-
RH23 (BK/OG), wiring harness side.

• Is a resistance of less than 2 Ohm registered?

→ Yes
TEST the PCM and RENEW it if necessary.
CHECK operation of system
→ No
LOCATE and RECTIFY the break in circuit
91S-RH23 (BK/OG) between PCM and re-
lay 1, coolant additional electric heating us-
ing the Wiring Diagrams. CHECK operation
of system
A16: CHECK VOLTAGE AT RELAY 2, COOLANT ADDITIONAL ELECTRIC HEATING
1 Key in OFF position.
2 Disconnect Relay 2, coolant additional electric
heating C126.
3 Measure the voltage between relay 2, coolant
additional electric heating, connector C126, pin
3, circuit 30-RH26 (RD), wiring harness side
and ground.

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412-02B-11 Auxiliary Heating 412-02B-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the meter display battery voltage?

→ Yes
GO to A17
→ No
LOCATE and RECTIFY the break in circuit
30-RH26 (RD) between relay 2, coolant ad-
ditional electric heating and solder point
S361 using the Wiring Diagrams. CHECK
operation of system
A17: CHECK CONTROL VOLTAGE AT RELAY 2, COOLANT ADDITIONAL ELECTRIC HEATING
1 Key in ON position.
2 Measure the voltage between relay 2, coolant
additional electric heating, connector C126, pin
1, circuit 15-RH25 (GN/BK), wiring harness
side and ground.

• Does the meter display battery voltage?

→ Yes
GO to A18
→ No
LOCATE and RECTIFY the break in circuit
15-RH25 (GN/BK) between relay 2, coolant
additional electric heating and fuse F82 us-
ing the Wiring Diagrams. Check operation of
system
A18: CHECK THE CIRCUIT BETWEEN RELAY 2, COOLANT ADDITIONAL ELECTRIC HEATING
AND THE COOLANT ADDITIONAL ELECTRIC HEATER FOR OPEN CIRCUIT.
1 Key in OFF position.
2 Measure the resistance between relay 2, cool-
ant additional electric heating, connector C126,
pin 5, circuit 15S-RH26 (GN/WH), wiring har-
ness side and ground.

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412-02B-12 Auxiliary Heating 412-02B-12

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is a resistance of less than 0,7 Ohm regis-

tered?
→ Yes
GO to A21
→ No
GO to A19
A19: CHECK THE COOLANT ADDITIONAL ELECTRIC HEATER
1 Disconnect Coolant additional electric heating
C124.
2 Measure the resistance between coolant addi-
tional electric heating, connector C124, pin 3,
circuit 15S-RH26B (GN/WH), component side
and ground.

• Is a resistance of less than 0,9 Ohm regis-

tered?
→ Yes
GO to A20
→ No
RENEW the coolant additional electric
heater. CHECK operation of system
A20: CHECK THE COOLANT ADDITIONAL ELECTRIC HEATER
1 Measure the resistance between coolant addi-
tional electric heating, connector C124, pin 5,
circuit 15S-RH26A (GN/WH), component side
and ground.

• Is a resistance of less than 0,9 Ohm regis-

tered?
→ Yes

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412-02B-13 Auxiliary Heating 412-02B-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the break in circuit
15S-RH26 (GN/WH), 15S-RH26A (GN/WH)
or 15S-RH26B (GN/WH) between relay 2,
coolant additional electric heating and the
coolant additional electric heater using the
Wiring Diagrams. CHECK operation of sys-
tem
→ No
RENEW the coolant additional electric
heater. CHECK operation of system
A21: CHECK RELAY 2, COOLANT ADDITIONAL ELECTRIC HEATING
1 Check relay 2, coolant additional electric heat-
ing in accordance with the component test at
the end of this section.
• Is relay 2, coolant additional electric heating
OK?
→ Yes
GO to A22
→ No
RENEW relay 2, coolant additional electric
heating CHECK operation of system
A22: CHECK THE CIRCUIT BETWEEN PCM AND RELAY 2, COOLANT ADDITIONAL ELECTRIC
HEATING FOR OPEN CIRCUIT
1 Disconnect PCM C100.
2 Measure resistance between relay 2, coolant
additional electric heating, socket C126, pin 2,
circuit 91S-RH25 (BK/GN), wiring harness side
and PCM, connector C100, pin 75, circuit 91S-
RH25 (BK/GN), wiring harness side.

• Is a resistance of less than 2 Ohm registered?

→ Yes
TEST the PCM and RENEW it if necessary.
CHECK system operates correctly
→ No
LOCATE and RECTIFY the break in circuit
91S-RH25 (BK/GN) between PCM and relay
2, coolant additional electric heating using
the Wiring Diagrams. CHECK system oper-
ates correctly

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412-02B-14 Auxiliary Heating 412-02B-14

DIAGNOSIS AND TESTING

Component Tests

Relay, coolant additional electric heating

1. Check the normally open contact in the
unswitched state.
• Measure the resistance at the relay,
between pin 3 and pin 5, component side.
• Is a resistance of more than 10 kOhms
registered? If yes, go to 2. If no, RENEW
the relay.

2. Check the normally open contact in the

switched state.
• Using a fused test cable (1 A), connect pin
1 of the relay, component side, with the
battery positive pole.
• Using a test cable, connect pin 2 of the
relay, component side, with the battery
negative pole.
• Measure the resistance at the relay,
between pin 3 and pin 5, component side.
• Is a resistance of less than 2 Ohm
registered? If yes, the relay is OK. If no,
RENEW relay.

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412-03-1 Air Conditioning 412-03-1

SECTION 412-03 Air Conditioning

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 412-03-2

DESCRIPTION AND OPERATION

Air Conditioning ................................................................................................................. 412-03-3

Air conditioning components............................................................................................. 412-03-4

DIAGNOSIS AND TESTING

Air Conditioning ................................................................................................................. 412-03-6

REMOVAL AND INSTALLATION

Air Conditioning (A/C) Compressor — 1.8L/2.0L/2.5L................................... (34 626 0) 412-03-7

Clutch and Clutch Field Coil — 1.8L/2.0L/2.5L ............................................. (34 628 0) 412-03-9
Evaporator Core ........................................................................................... (34 622 0) 412-03-12
Evaporator Core Orifice ................................................................................ (34 624 0) 412-03-13
Suction Accumulator..................................................................................... (34 630 0) 412-03-15
Low-Pressure Cutoff Switch ......................................................................... (34 629 0) 412-03-17
High-Pressure Cutoff Switch......................................................................... (34 631 0) 412-03-19
Condenser Core ........................................................................................... (34 632 0) 412-03-20

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412-03-2 Air Conditioning 412-03-2

SPECIFICATIONS

Air Conditioning (A/C) Compressor

Type
Air conditioning (A/C) compressor (Vehicles with diesel engine) FS10
Air conditioning (A/C) compressor (Vehicles with petrol engine) FVS 090

Evaporator Core Orifice

Color
Evaporator core orifice Orange

Torque Specifications
Description Nm lb-ft lb-in
Air conditioning (A/C) compressor heat shield (Ve- 10 – 89
hicles with 2.5L engine)
Refrigerant line to air conditioning (A/C) compres- 20 15 –
sor union
Air conditioning (A/C) compressor retaining bolts 25 18 –
Air conditioning (A/C) compressor drive plate re- 13 10 –
taining bolt
Evaporator core orifice connection 14 10 –
High-pressure cutoff switch 8 – 71
Low-pressure cutoff switch 2.5 – 23
Refrigerant line to condenser core unions 8 – 71
Condenser core retaining bolts 9 – 80
Refrigerant line to suction accumulator unions 8 – 71
Suction accumulator 8 – 71
Strut and spring assembly reinforcement retaining 20 15 –
bolts
Strut and spring assembly retaining nuts 30 22 –
Engine undershield 10 – 89

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412-03-3 Air Conditioning 412-03-3

DESCRIPTION AND OPERATION

Air Conditioning
DESCRIPTION AND OPERATION

low-pressure cutoff switch. R134a refrigerant is

used.
The air conditioning (A/C) system contains a
evaporator core orifice and is controlled by the

Refrigerant Circuit

Item Part Description

Item Part Description Number
Number
9 - Low-pressure (liquid and
1 - Condenser core cool)
2 - Air conditioning (A/C) com- 10 - Low-pressure (gaseous and
pressor cool)
3 - Suction accumulator 11 - High-pressure (gaseous and
4 - Blower motor hot)

5 - Evaporator core The A/C compressor (2) is driven by the engine.

The A/C compressor primes the gaseous
6 - Evaporator core orifice refrigerant out of the suction accumulator (3) and
7 - Condenser fan motor compresses it. The refrigerant heats up and is
passed to the condenser core (1) under high-
8 - High-pressure (liquid and pressure.
warm)

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412-03-4 Air Conditioning 412-03-4

DESCRIPTION AND OPERATION (Continued)

At this point heat is drawn from the refrigerant by coming from the evaporator core enters the
the air being forced past the cooling fins. suction accumulator and is primed up again by
Because of this heat loss, the refrigerant liquifies the A/C compressor.
and leaves the condenser core.
The system is protected by the high-pressure
A evaporator core orifice (6), which separates the cutoff switch, in order to prevent damage by
refrigerant at high-pressure from that at low- excessive pressure (example, because of
pressure, is located between the condenser core overfilling). If the pressure exceeds the maximum
and the evaporator core (5). This evaporator core allowed, the high-pressure cutoff switch turns off
orifice slows down the flow of the refrigerant from the A/C compressor.
the A/C compressor, so that pressure builds up in
The working cycles of the A/C compressor are
the condenser core.
controlled by the low-pressure cutoff switch
After passing through the evaporator core orifice depending on the low-pressure in the suction
the liquid refrigerant expands in the circuit to the accumulator. The low-pressure cutoff switch
evaporator core. In the evaporator core the liquid turns the A/C compressor off permanently if the
refrigerant converts back into the gaseous state pressure falls below the approved value
and this causes heat to be extracted from the air (example, if there is a leak).
coming into the vehicle. The air therefore cools
down and the moisture it contained is given up at
the evaporator core. The refrigerant stream Air conditioning components

Item Description
1 Evaporator core orifice
2 Evaporator core connections
3 A/C compressor
4 Condenser core connections
5 Suction accumulator

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412-03-5 Air Conditioning 412-03-5

DESCRIPTION AND OPERATION (Continued)

Item Description
6 Low-pressure cutoff switch
7 High-pressure cutoff switch

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412-03-6 Air Conditioning 412-03-6

DIAGNOSIS AND TESTING

Air Conditioning
DIAGNOSIS AND TESTING

REFER to Section 412-00.

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412-03-7 Air Conditioning 412-03-7

REMOVAL AND INSTALLATION

Air Conditioning (A/C) Compressor — 1.8L/2.0L/2.5L (34 626 0)

REMOVAL AND INSTALLATION

Removal Vehicles with 2.5L Engine

5. Remove the heat shield from the A/C com-
All vehicles
pressor clutch (exhaust pipe shown re-
1. Evacuate the air conditioning (A/C)
moved for clarity).
system.For additional information, refer to
Section 412-00.
2. Disconnect the A/C compressor clutch
connector.

6. CAUTION: Support the A/C

compressor before removing the
retaining bolts.
3. Remove the accessory drive belt.For Remove the A/C compressor.
additional information, refer to Section
303-05.
4. CAUTION: Cap the refrigerant lines and
the A/C compressor to prevent dirt
ingress.
Detach the refrigerant lines from the A/C
compressor. (1.8L engine shown).
• Discard the O-ring seals.

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412-03-8 Air Conditioning 412-03-8

REMOVAL AND INSTALLATION (Continued)

Vehicles with 1.6L, 1.8L or 2.0L engine
7. CAUTION: Support the A/C
compressor before removing the
retaining bolts.
Remove the A/C compressor.

Installation
1. NOTE: Install new refrigerant line O-ring seals.
NOTE: Coat the refrigerant line O-ring seals with
clean refrigerant oil prior to installation.
Install the components in the reverse
order.

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412-03-9 Air Conditioning 412-03-9

REMOVAL AND INSTALLATION

Clutch and Clutch Field Coil — 1.8L/2.0L/2.5L (34 628 0)

All vehicles
CAUTION: Support the A/C compressor
General Equipment before removing the retaining bolts and
Two leg puller secure it to prevent load being placed on
the refrigerant lines.
M6 x 30 mm bolt NOTE: Mark the position of the A/C compressor
Washer clutch electrical connector in relation to the
compressor housing.
4. Detach the A/C compressor from the A/C
Removal compressor bracket.

All vehicles
1. Disconnect the air conditioning (A/C)
compressor clutch electrical connector.

5. Remove the A/C compressor drive plate.

2. Remove the accessory drive belt. For

additional information, refer to Section
303-05.
Vehicles with the 2.5L engine
3. Remove the A/C compressor heat shield
(shown with removed exhaust pipe for
clarity).

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412-03-10 Air Conditioning 412-03-10

REMOVAL AND INSTALLATION (Continued)

6. Remove the A/C compressor pulley. 1. Using a suitable M6 x 30 mm bolt, a suit-
• Remove the spacer shims. able washer and the A/C compressor drive
plate, install the clutch field coil.

7. Using a suitable two leg puller, remove the

clutch field coil.

2. Remove the M6 x 30 mm bolt, washer and

A/C compressor drive plate.
1. Install the spacer shims.
3. NOTE: Install a new A/C compressor pulley
snap ring.
Install the A/C compressor pulley.
• Install the snap ring.

Installation
All vehicles
NOTE: Do not skew the clutch field coil when
installing it to the A/C compressor seat.

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412-03-11 Air Conditioning 412-03-11

REMOVAL AND INSTALLATION (Continued)

4. Install the A/C compressor drive plate. All vehicles

8. Install the accessory drive belt. For
additional information, refer to Section
303-05.
9. Connect the A/C compressor clutch elec-
trical connector.

5. Check the A/C clutch air gap. For

additional information, refer to Section
412-00.
6. Attach the A/C compressor to the A/C
compressor bracket.

Vehicles with the 2.5L engine

7. Install the A/C compressor heat shield
(shown with removed exhaust pipe for
clarity).

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412-03-12 Air Conditioning 412-03-12

REMOVAL AND INSTALLATION

Evaporator Core (34 622 0)

Removal 5. Separate the evaporator core housing.

1. Remove the heater core and evaporator
core housing. For additional information,
refer to Section 412-02A / 412-02B.
2. Remove the evaporator core upper hous-
ing.

6. Remove the evaporator core.

3. Remove the rubber seal.

Installation
1. To install, reverse the removal procedure.

4. Remove the evaporator core retaining bolt.

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412-03-13 Air Conditioning 412-03-13

REMOVAL AND INSTALLATION

Evaporator Core Orifice (34 624 0)

3. Remove the right-hand suspension strut

Special Tool(s) nuts.

Remover/Installer,
Evaporator Core Orifice
412-034 (34-004)

Remover, Broken Evaporator

Core Orifice
412-035 (34-005)

Removal All vehicles

4. Evacuate the air conditioning (A/C)
Vehicles with diesel engine system.For additional information, refer to
Section 412-00.
CAUTION: Do not raise the vehicle.
1. Remove the right-hand suspension strut 5. Unclip the refrigerant line from the evapo-
cover (left-hand side shown). rator core orifice.

2. Remove the right-hand suspension strut 6. Detach the refrigerant line.

nuts (left-hand side shown). • Discard the O-ring seals.

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412-03-14 Air Conditioning 412-03-14

REMOVAL AND INSTALLATION (Continued)

7. Using the special tool, remove the

evaporator core orifice.
• Guide the tool into the tube and hook it into
the evaporator core orifice.
• Turn the tool clockwise and pull out the
evaporator core orifice.

8. NOTE: Only necessary if the evaporator core

orifice is broken.
Using the special tools, remove the broken
evaporator core orifice.

Installation
1. NOTE: Install new refrigerant line O-ring seals.
NOTE: Coat the refrigerant line O-ring seals with
clean refrigerant oil prior to installation.
Install the components in the reverse
order.

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412-03-15 Air Conditioning 412-03-15

REMOVAL AND INSTALLATION

Suction Accumulator (34 630 0)

5. Disconnect the A/C low-pressure switch
connector.
Special Tool(s)
Disconnect Tool, Spring Lock
Coupling 3/4 inch (white)
412-069 (34-002)

Removal
1. Evacuate the air conditioning (A/C)
system.For additional information, refer to
Section 412-00.
2. Raise the vehicle.For additional CAUTION: Cap the refrigerant lines and
information, refer to Section 100-02. the suction accumulator/dryer
3. Remove the radiator shield. connections to prevent dirt ingress.
6. Detach the refrigerant line from the suction
accumulator/dryer.
• Discard the O-ring seals.

4. Remove the right-hand wheel arch trim

panel (shown without wheel for clarity).

7. Detach the refrigerant line from the suction

accumulator/dryer using the special tool.
• Discard the O-ring seals.

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412-03-16 Air Conditioning 412-03-16

REMOVAL AND INSTALLATION (Continued)

8. Remove the windscreen wiper reservoir

(front bumper cover shown removed for
clarity).

9. Remove the suction accumulator/drier.

Installation
1. NOTE: Install new refrigerant line O-ring seals.
NOTE: Coat the refrigerant line O-ring seals with
clean refrigerant oil prior to installation.
Install the components in the reverse
order.

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412-03-17 Air Conditioning 412-03-17

REMOVAL AND INSTALLATION

Low-Pressure Cutoff Switch (34 629 0)

Removal 4. Start the engine and turn the air

conditioning (A/C) switch to the ON
1. Remove the right-hand fender splash
position.
shield lower retaining screws.
5. NOTE: The A/C compressor must run during
low-pressure cutoff switch removal.
Connect a 20 A fuse rated jumper wire be-
tween Pin 1 and Pin 4, harness side, of the
low-pressure cutoff switch electrical con-
nector.

2. Detach the right-hand fender splash shield

and push it to one side (wheel shown re-
moved for clarity).

6. NOTE: Make sure that the low-pressure cutoff

switch valve closes completely after removal
of the low-pressure cutoff switch to prevent
loss of refrigerant.
Remove the low-pressure cutoff switch.
• Discard the O-ring seals.

3. Disconnect the low-pressure cutoff switch

electrical connector.

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412-03-18 Air Conditioning 412-03-18

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Install new low-pressure cutoff switch
O-ring seals.
NOTE: Coat the low-pressure cutoff switch O-
ring seals in clean refrigerant oil prior to
installation.
NOTE: Thighten the low-pressure cutoff switch
carefully to prevent any damage.
To install, reverse the removal procedure.

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412-03-19 Air Conditioning 412-03-19

REMOVAL AND INSTALLATION

High-Pressure Cutoff Switch (34 631 0)

Removal
1. Disconnect the high-pressure cutoff
switch electrical connector.

2. NOTE: Make sure that the high-pressure cutoff

switch valve closes completely after removal
of the high-pressure cutoff switch to prevent
loss of refrigerant.
Remove the high-pressure cutoff switch.
• Discard the O-ring seals.

Installation
1. NOTE: Install new high-pressure cutoff switch
O-ring seals.
NOTE: Coat the high-pressure cutoff switch O-
ring seals in clean refrigerant oil prior to
installation.
To install, reverse the removal procedure.

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412-03-20 Air Conditioning 412-03-20

REMOVAL AND INSTALLATION

Condenser Core (34 632 0)

Removal
5. CAUTION: Cap the refrigerant lines and
All vehicles the A/C condenser core to prevent dirt
1. Evacuate the air conditioning (A/C) ingress.
system.For additional information, refer to Disconnect the refrigerant lines from the
Section 412-00. A/C condenser core.
Vehicles with 2.0L diesel engine and 5-speed • Discard the O-ring seals.
automatic transmission (front wheel drive)
2. Secure the radiator at both sides using
suitable cable ties.

6. Remove the A/C condenser core fastening

bolts.

All vehicles
3. Raise the vehicle.For additional
information, refer to Section 100-02.
4. Remove the lower radiator cover.

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412-03-21 Air Conditioning 412-03-21

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.0L diesel engine and 5-speed All vehicles

automatic transmission (front wheel drive) 9. Remove the A/C condenser core.
7. Remove the radiator support bracket.

8. CAUTION: Cap the hoses and the oil Installation

cooler to prevent dirt ingress.
NOTE: Mark the installation position of the feed All vehicles
and return hose. NOTE: Install new refrigerant line O-ring seals.
NOTE: Allow the automatic transmission fluid to NOTE: Coat the refrigerant line O-ring seals with
drain into a suitable container. clean refrigerant oil prior to installation.
Remove the automatic transmission oil 1. Install the components in the reverse
cooler hoses. order.
Vehicles with 2.0L diesel engine and 5-speed
automatic transmission (front wheel drive)
2. Check the transmission fluid level.For
additional information, refer to Section
307-01A / 307-01B.

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412-04-1 Control Components 412-04-1

SECTION 412-04 Control Components

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Control Components.......................................................................................................... 412-04-2

Climate Control Assembly - Vehicles with Manual Temperature Control .......................... 412-04-2
Climate Control Assembly - Vehicles with Automatic Temperature Control ...................... 412-04-2

DIAGNOSIS AND TESTING

Control Components.......................................................................................................... 412-04-3

REMOVAL AND INSTALLATION

Climate Control Assembly ............................................................................ (34 300 0) 412-04-4

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412-04-2 Control Components 412-04-2

DESCRIPTION AND OPERATION

Control Components
DESCRIPTION AND OPERATION

Climate Control Assembly - Vehicles with

Manual Temperature Control
Vehicles with manual temperature control have a
climate control assembly with three rotary
switches.The position of the temperature door,
defrost vent nozzle and air distribution door are
controlled by the control module incorporated in
the control unit and actuated electronically by
means of control motors. The air recirculation
valve is controlled by an actuating switch and
actuated electronically by means of a control
motor. Furthermore the actuating buttons for the
air conditioning and air recirculation are located
on the climate control assembly.

Climate Control Assembly - Vehicles with

Automatic Temperature Control
Vehicles with automatic temperature control have
a climate control assembly with several buttons.
Two buttons for the interior temperature setting,
two buttons for the blower speed and four buttons
for the air flow direction. Furthermore the
actuating buttons for the air conditioning and air
recirculation are located on the climate control
assembly.
The digital display has been enlarged to the
display of the previous model and displays the
blower speed setting, the demist/defrost mode,
the air flow direction indicator, the air conditioning
automatic mode and the selected interior
temperature.

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412-04-3 Control Components 412-04-3

DIAGNOSIS AND TESTING

Control Components
DIAGNOSIS AND TESTING

REFER to Section 412-00.

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412-04-4 Control Components 412-04-4

REMOVAL AND INSTALLATION

Climate Control Assembly (34 300 0)

REMOVAL AND INSTALLATION

Removal
1. Remove the audio unit. For additional 5. NOTE: Use a pad under the screwdriver to
information, refer to Section 415-01. prevent damage to the instrument panel
center bezel.
2. Remove the instrument panel center bezel
rear retaining screws. Detach the operating switches from the
instrument panel center bezel.

3. Detach the gearshift lever boot from the

floor console. 6. Remove the operating switches.
• Disconnect the electrical connectors.

4. Remove the instrument panel center bezel

lower retaining screws.

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412-04-5 Control Components 412-04-5

REMOVAL AND INSTALLATION (Continued)

7. Remove the instrument panel center bezel

upper retaining screws.

8. Disconnect the climate control assembly

electrical connector.

9. Remove the climate control assembly.

Installation
1. To install, reverse the removal procedure.

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413-00-1 Instrument Cluster and Panel Illumination 413-00-1

SECTION 413-00 Instrument Cluster and Panel

Illumination
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Instrument Cluster and Panel Illumination.......................................................................... 413-00-2

Inspection and Verification ............................................................................................... 413-00-2

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413-00-2 Instrument Cluster and Panel Illumination 413-00-2

DIAGNOSIS AND TESTING

Instrument Cluster and Panel Illumination

DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern .
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Fluid level(s) – Bulb(s)
– Accessory installa- – Fuse(s)
tions – Wiring harness
– Electrical
connector(s)
– Engine/engine
compartment or
underbody
components
– Instrument cluster
– Instrument cluster
printed circuit
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

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413-01-1 Instrument Cluster 413-01-1

SECTION 413-01 Instrument Cluster

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Instrument Cluster ............................................................................................................. 413-01-2

Instrument Cluster ............................................................................................................ 413-01-2
Information and Message Center ..................................................................................... 413-01-3

DIAGNOSIS AND TESTING

Instrument Cluster ............................................................................................................. 413-01-4

Principles of Operation ..................................................................................................... 413-01-4
Instrument Cluster Gauges............................................................................................... 413-01-4
Warning Indicators ........................................................................................................... 413-01-5
Information and Message Center Indicators and Warning Indicators ................................ 413-01-7
Control Area Network (CAN) ............................................................................................ 413-01-7
Configuration of Instrument Cluster .................................................................................. 413-01-7
Inspection and Verification ............................................................................................... 413-01-7
Self-Diagnostic Mode ....................................................................................................... 413-01-8
Symptom Chart ................................................................................................................ 413-01-9

REMOVAL AND INSTALLATION

Instrument Cluster ........................................................................................ (33 214 0) 413-01-11

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413-01-2 Instrument Cluster 413-01-2

DESCRIPTION AND OPERATION

Instrument Cluster
DESCRIPTION AND OPERATION

Instrument Cluster

Item Part Description

Item Part Description Number
Number
9 - Door ajar indicator
1 - Glow plug indicator (if
equipped) 10 - Parking brake/brake warning
indicator
2 - Ice warning indicator (red)
11 - RH turn signal indicator
3 - Frost warning indicator (or-
ange) 12 - Safety belt warning indicator

4 - Tachometer 13 - Air bag warning indicator

5 - High beam indicator 14 - Speedometer

6 - LH turn signal indicator 15 - Malfunction indicator lamp

(MIL)
7 - Charging system warning
indicator 16 - Low fuel level indicator

8 - Low oil pressure warning in- 17 - Fuel gauge

dicator 18 - Odometer

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413-01-3 Instrument Cluster 413-01-3

DESCRIPTION AND OPERATION (Continued)

Item Part Description Item Part Description

Number Number
19 - Stability assist indicator 22 - Information and message
center
20 - Anti-lock brake system
(ABS) warning indicator 23 - Temperature gauge
21 - Headlamp indicator

Information and Message Center

Item Part Description

Item Part Description Number
Number
7 - Range to empty indicator -
1 - Trip computer (average fuel right-hand drive vehicles
economy indicator, average
speed indicator, outside air 8 - Vehicle speed control indica-
temperature indicator, range tor (if equipped)
to empty indicator) 9 - Overdrive indicator - vehi-
2 - Average fuel economy indi- cles with automatic transaxle
cator - right-hand drive vehi- For additional information. REFER to the Owners
cles Guide.
3 - Average speed indicator -
right-hand drive vehicles
4 - Average speed indica-
tor/range to empty indicator -
left-hand drive vehicles
5 - Range to empty indicator -
all vehicles
6 - Average fuel economy indi-
cator - left-hand drive vehi-
cles

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413-01-4 Instrument Cluster 413-01-4

DIAGNOSIS AND TESTING

Instrument Cluster
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 413-01 for

– ABS
schematic and connector information.
– Air bag system
– Charging system (the indicator is functional
Principles of Operation but will illuminate with the during the test)
The instrument cluster is a mix of intelligent and – Brake system
hardwired electrical signals and has a built-in – Low fuel
self-test feature. The instrument cluster is – Low oil pressure
connected to the powertrain control module – Malfunction indicator lamp (MIL)
(PCM), anti-lock brake system (ABS), traction
control (TC) (if equipped) and stability assist (if – TC (if equipped)
equipped) by a control area network (CAN) bus. – Overdrive (displayed in a liquid crystal display
This link allows the instrument cluster and the (LCD)) (if equipped)
PCM to communicate with each other. The – Glow plugs - Vehicles with diesel engine
instrument cluster consists of gauges, indicators – Frost (orange)
and warning indicators. On the high series
– Ice (red)
instrument cluster a trip computer is fitted to the
information and message center. – Safety belt
– Speed control (displayed in LCD)
When the ignition switch is turned to position II
from either position 0 or position I the instrument – Door ajar
cluster carries out a display test to verify that the
warning indicators or indicator bulbs and
monitored systems are functioning correctly. The Instrument Cluster Gauges
warning indicators or indicator bulbs which
illuminate during this test are: Engine Temperature Gauge
The engine temperature gauge uses information
supplied by the engine coolant temperature
(ECT) or the cylinder head temperature (CHT)
sensor, through the PCM on the CAN bus. If the
temperature signal is missing or invalid, the
instrument cluster will move the temperature
gauge pointer to below the cold position.

Fuel Gauge
The instrument cluster receives the fuel level
information from the fuel level sensor (part of the
fuel pump module on vehicles with a petrol
engine). This is a variable resistor in the fuel
gauge ground circuit. If the fuel level signal is
missing or invalid, the instrument cluster will
move the fuel gauge pointer to below the empty
position and the low fuel warning indicator will
illuminate.
The fuel gauge signal is damped to prevent
pointer surge as the fuel in the fuel tank moves
while the vehicle is in motion. When the ignition
switch is turned to position 0 the fuel gauge
pointer is moved to below the empty position.

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413-01-5 Instrument Cluster 413-01-5

DIAGNOSIS AND TESTING (Continued)

Speedometer indicator. This information is also based on

calculations from the range to empty display.
Vehicle speed information is received by the
PCM from the vehicle speed sensor (VSS). The
PCM calculates the vehicle speed using various ABS Warning Indicator
factors one of these being tire size. The vehicle
speed information is sent to the instrument The instrument cluster receives the ABS
cluster through the CAN bus, the vehicle speed information from the ABS module. If the ABS
information is then indicated in m.p.h.or km/h on module detects an open circuit, a short to battery,
the speedometer gauge. If this information is or an ABS failure the ABS warning indicator will
missing or invalid, the speedometer will default to illuminate. REFER to Section 206-09A / 206-09B.
zero. The ABS Warning indicator must be enabled
when a new instrument cluster is installed. For
If the tire size is changed from that originally fitted additional information REFER to Programmable
it may be necessary to change the PCM Module Installation Routine on WDS.
configuration. This can be done using WDS.
Brake System Warning Indicator
Odometer
The brake system warning indicator has multiple
Vehicle speed information is received by the functions. The warning indicator illuminates if the
PCM from the VSS. The PCM uses the brake fluid level is low or if the parking brake is
configured tire size to calculate distance travelled set or if the electronic brake distribution (EBD) fail
and inputs this information to the instrument input is high. REFER to Section 206-00.
cluster through the CAN bus. The instrument
cluster displays this information in an LCD. If this
information is missing or invalid, the LCD will Charging System Warning Indicator
display dashes. Also incorporated in this LCD is a The PCM controls the charging system warning
tripmeter. indicator through the CAN bus. The warning
indicator is illuminated if the charging system is
Tachometer
not operating correctly, or if the ignition switch is
turned to position II but the engine is not running.
Engine speed information is received by the PCM REFER to Section 414-00. This signal is sent to
from the crankshaft position (CKP) and camshaft the generic electronic module (GEM) and fuel
position (CMP) sensors. The engine speed fired heater (if equipped). The signal is used by
information is sent to the instrument cluster the GEM to control when the fuel fired heater can
through the CAN bus. If this information is be activated.
missing or invalid, the tachometer will default to
zero.
Traction Control (TC) Warning Indicator (if
equipped)
Warning Indicators The TC indicator is controlled by the ABS/TC
module. The TC indicator flashes to indicate
Air Bag Warning Indicator
when a concern is present. REFER to Section
206-09A / 206-09B. This information is provided
The air bag warning indicator is controlled by the to the instrument cluster through the CAN bus.
air bag module. REFER to Section 501-20A / The TC system can be disabled by pressing the
501-20B. TC OFF button which is located in the instrument
panel center console.
Low Fuel Warning Indicator If the TC indicator is required it must be enabled
when a new instrument cluster is installed. For
The instrument cluster receives the fuel level
additional information REFER to Programmable
information from the fuel level sensor (part of the
Module Installation Routine on WDS.
fuel pump module on vehicles with a petrol
engine). When the fuel level in the fuel tank drops
below a predetermined limit the low fuel warning
indicator receives a direct signal from the fuel
level sensor and illuminates the low fuel warning
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413-01-6 Instrument Cluster 413-01-6

DIAGNOSIS AND TESTING (Continued)

Low Oil Pressure Warning Indicator the instrument cluster. The high beam indicator
has a permanent ground and therefore when the
The low oil pressure warning indicator has a
power is supplied the indicator illuminates.
direct connection to the engine oil pressure
switch through the instrument cluster. With the
ignition switch in position II, the low oil pressure Left and Right Turn Signal Indicators
warning indicator illuminates. After the engine is
started, the oil pressure switch opens at a The left and right turn signal indicators have a
predetermined pressure, breaking the ground direct connection to the GEM. The GEM provides
circuit continuity which extinguishes the oil a permanent ground to the turn signal indicators.
pressure warning indicator. When the left or right turn signals are selected on
the steering column multifunction switch power is
sent through the GEM and instrument cluster to
Door Ajar Warning Indicator
illuminate the left and right turn signal indicators.
The door ajar indicator is controlled by the GEM.
The system operates by supplying a ground
Malfunction Indicator Lamp (MIL)
when the GEM detects a door(s) or
liftgate/luggage compartment lid which is opened The MIL illuminates where the exhaust emissions
or not fully closed, which will illuminate the are affected and an appropriate diagnostic
indicator. The GEM has a direct connection to the trouble code (DTC) is registered in the PCM.
door ajar indicator through the instrument cluster.
When an emission related DTC is registered in
the PCM, the PCM will send a signal through the
Frost Warning Indicator or Ice Warning Indicator CAN bus to the instrument cluster to illuminate
the MIL. The DTC and associated concern must
The ambient temperature is provided by the be rectified and cleared from the PCM memory
ambient temperature sensor to the PCM. The for the MIL to extinguish.
PCM provides this signal to the instrument cluster
through the CAN bus. When the ambient
temperature falls to 4°C (40°F) there is an Liftgate/Luggage Compartment Release Inhibit
audible chime from the GEM and the amber frost
The GEM uses a direct connection to the
warning indicator illuminates. When the ambient
instrument cluster to ascertain the current vehicle
temperature falls to 0°C (32°F) or below, the red
speed. If the vehicle speed is above 3 m.p.h. (5
ice warning indicator illuminates and the amber
km/h) the GEM will inhibit the liftgate/luggage
frost warning indicator extinguished. This is to
compartment lid from being opened using the
alert the driver to the possibility of icy roads.
remote luggage compartment release.

Glow Plug Warning Indicator - Vehicles with Diesel

Ambient Temperature
Engine
The ambient temperature is provided by the
The glow plug warning indicator will illuminate
ambient temperature sensor to the PCM. The
when the ignition is in the ON position with the
PCM provides this signal to the instrument cluster
engine OFF while the glow plugs are heating.
through the CAN bus. The ambient temperature
The glow plug warning indicator is controlled by
is displayed in the left-hand LCD in the
the PCM through the CAN bus. The glow plug
instrument cluster. To change the ambient
warning indicator will also flash to indicate the
temperature from °C to °F press the left-hand
presence of a hard DTC. REFER to Section 303-
reset button.
04A / 303-04B.

Warning Chimes
High Beam Indicator
All warning chimes are generated by the GEM.
The high beam indicator has a direct connection
The following warning chimes can be requested
to the steering column multifunction switch
by the instrument cluster through the GEM to
through the instrument cluster.
function on the vehicle:
When high beam is selected on the steering
column multifunction switch power is sent by a
direct connection to the high beam indicator in
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413-01-7 Instrument Cluster 413-01-7

DIAGNOSIS AND TESTING (Continued)

• Reverse gear selected (if equipped) Gear Selection Display - Vehicles with 5-speed
• Low fuel Automatic Transaxle
• Distance to fuel tank empty This function indicates what mode and gear the
• Frost/ice warning vehicle is in. If the transaxle is in automatic mode
• Overspeed chime (configurable if equipped) the display will show 'AUTO' and the selector
lever indicator will display the gear selected. If
• Trip computer mode select the transaxle is in manual mode the display will
show 'MAN' and the selector lever indicator will
display the gear selected. The gear selection
Information and Message Center Indicators display is located in the information and message
and Warning Indicators center which is located in the left-hand LCD of
The information and message center is located in the instrument cluster
the left-hand LCD of a high series instrument
cluster. The information and message center can
supply the driver with the following information. Control Area Network (CAN)
All the functions within the information and The CAN is an electronic link enabling the
message center can be selected by pressing the instrument cluster to communicate with the PCM,
INFO button on the directional indicator switch. ABS/TC module and stability assist module. This
creates a pathway through the data link
– Average speed
connector (DLC) for WDS, although WDS uses
– Range to empty the ISO link to access the instrument cluster
– Average fuel economy control systems. This increases the WDS
– Outside air temperature diagnostic capabilities.

Average Speed Configuration of Instrument Cluster

This function indicates the average vehicle speed The instrument cluster is a programmable
calculated during the last 500 miles (804 km), or module, which must be configured by selecting
since the last reset. Press the left-hand reset the Programmable Module Installation Routine on
button in the instrument cluster for 3 seconds at WDS.
any time to reset the average speed calculated.
The following features will need to be configured
when a new instrument cluster is installed:
Range to Empty
• Overspeed chime (if equipped)
This function indicates the approximate distance • Speed control (if equipped)
the vehicle will travel using the remaining fuel in
• TC indicator (if equipped)
the fuel tank. Changes in driving pattern may
cause this figure to vary. A short audible chime • Reverse warning chime (if equipped)
will be emitted when the remaining distance is 50
miles (80 km), 25 miles (40 km) and 10 miles (20
km). Inspection and Verification
1. Verify the customer concern.
Average Fuel Economy 2. Visually inspect for obvious signs of
mechanical or electrical damage.
This function indicates the average fuel
consumption of the vehicle since the function was
Visual Inspection Chart
last reset. Press the left-hand reset button in the
instrument cluster for 3 seconds at any time to
reset the average fuel economy.

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413-01-8 Instrument Cluster 413-01-8

DIAGNOSIS AND TESTING (Continued)

Mechanical Electrical 4. Verify the following systems are working
correctly by operating the system.
– Engine oil filter – Fuse(s)
• Charging
– Oil pump – Bulb(s)
• Turn signals
– Engine oil level – LED(s)
• Headlamps
– Oil pressure switch – Wiring harness
5. If the concern remains after the inspection,
– Engine coolant level – Electrical enter the instrument cluster Self-Diagnostic
– Coolant thermostat connector(s) Mode.
– Fuel gauge – Sensor(s)
– Door adjustment – Instrument cluster
– Instrument cluster Self-Diagnostic Mode
printed circuit 1. To enter the instrument cluster Self-
3. If an obvious cause for an observed or Diagnostic Mode simultaneously press and
reported concern is found, correct the cause hold the tripmeter reset button and turn the
(if possible) before proceeding to the next ignition switch to position II.
step. 2. When TEST is displayed in the LCD release
NOTE: If all of the following systems are not the tripmeter reset button
operating correctly this may indicate a concern 3. The instrument cluster will enter the gauge
with the GEM. If one or more of the following sweep test.
systems operate correctly this may indicate an 4. To navigate through or skip any of the
instrument cluster concern. instrument cluster Self-Diagnostic Mode tests
press the tripmeter RESET button.
5. The self-test is deactivated when the ignition
switch is turned to the OFF position or when
the tripmeter reset button is pressed and held
for 5 seconds.
6. If Self-Diagnostic Mode cannot be accessed
use WDS to diagnose instrument cluster.
NOTE: Additional tests are available after the
following but are not applicable for this
diagnostic.

Self - Diagnostic Mode

Message Gauge/Indicator/Display/Inp
Test Displayed uts/System Tested Description
1. Gauge sweep GAGE Tachometer, speedometer, All gauges go through a full up
temperature and fuel and down pointer sweep
smoothness check, which
takes approximately 5 sec-
onds
2.All LCD are illumi- 8888 LCD displays built into Speed- Fills in all segments of LCD
nated ometer and Tachometer display therefore seeing if dis-
play functioning correctly

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413-01-9 Instrument Cluster 413-01-9

DIAGNOSIS AND TESTING (Continued)

Message Gauge/Indicator/Display/Inp
Test Displayed uts/System Tested Description
3. Indicator bulbs bulb Instrument cluster illuminates Illuminates the following
indicators and warning indica- warning indicators that are
tors controlled by the instrument
cluster
• ABS
• Brake warning
• Glow plugs (if equipped)
• Frost warning (orange)
• Ice warning (red)
• Low fuel
• MIL
• TC (if equipped)
4. ROM level rXXXX Instrument cluster read only Displays the instrument cluster
memory (ROM) ROM revision level
5. NVM (ROM) level ErXXXX Instrument cluster non volatile Displays the instrument cluster
memory (NVM) NVM revision
6. EEPROM level E XX Instrument cluster EEPROM Displays the instrument cluster
level EEPROM revision
7. DTC DTC or NONE DTCs The DTCs stored will be dis-
played. The DTC codes will
scroll through if there is more
than one
8. Road speed m.p.h. SPXXXX Speedometer Displays the current vehicle
speed input in m.p.h.
9. Road speed Km/h SPXXXX Speedometer Displays the current vehicle
speed signal input in Km/h
10. Engine speed tAXXXX Tachometer Displays the current engine
speed tachometer input signal
(RPM)
11. Fuel volume FXXX Fuel level sensor Displays the fuel volume sig-
nal input (0 = empty, 255 =
full)
12.ECT/CHT XXXC ECT/CHT Displays the temperature sig-
nal input in degrees C
13. Battery voltage btXXX Battery voltage Displays battery voltage input
7. REFER to WDS to continue diagnostics. information and message center in place of
the selector lever indicator. GO to Symptom
8. On vehicles with 5-speed automatic
Chart for further diagnosis.
transaxle, if two dashes are shown on the
Symptom Chart

Condition Possible Sources Action

• The information and message • Transmission range (TR) sen- • CHECK the TR sensor. REFER
center selector lever indicator sor. to Section 307-01A / 307-01B.
displays two dashes
• Circuit. • CARRY out wiring checks be-
tween theTR sensor and the in-
strument cluster. REFER to wir-
ing diagrams.

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413-01-10 Instrument Cluster 413-01-10

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Instrument cluster. • REFER to WDS.

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413-01-11 Instrument Cluster 413-01-11

REMOVAL AND INSTALLATION

Instrument Cluster (33 214 0)

REMOVAL AND INSTALLATION

Removal 3. Remove the audio control switch (if

equipped).
NOTE: If a new instrument cluster is being
installed connect WDS. Upload the instrument • Disconnect the electrical connector.
cluster configuration information using the
programmable modules installation routine prior
to commencing the removal of the instrument
cluster.
1. Remove the instrument panel lower panel.
1. Remove the retaining screws.
2. Release the retaining clips.

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.

2. Detach the audio control switch from the

steering column lower shroud (if
equipped).
• Using a thin bladed screwdriver, release
the locking tang.

5. Remove the steering column upper

shroud.

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413-01-12 Instrument Cluster 413-01-12

REMOVAL AND INSTALLATION (Continued)

9. Remove the instrument cluster retaining
6. Remove the steering column lower shroud.
screws and detach the instrument cluster.

7. Remove the instrument cluster finish panel

retaining screws. (Steering wheel shown 10. CAUTION: The instrument cluster
removed for clarity). 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.

8. Remove the instrument cluster finish

panel.

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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413-06-1 Horn 413-06-1

SECTION 413-06 Horn

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 413-06-2

DIAGNOSIS AND TESTING

Horn .................................................................................................................................. 413-06-3

Inspection and Verification ............................................................................................... 413-06-3
Symptom Chart ................................................................................................................ 413-06-3
Pinpoint Tests .................................................................................................................. 413-06-3

REMOVAL AND INSTALLATION

Horn Switch .................................................................................................. (33 523 0) 413-06-11

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413-06-2 Horn 413-06-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Horn switch retaining bolts 4 - 35

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413-06-3 Horn 413-06-3

DIAGNOSIS AND TESTING

Horn
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 413-06 for Electrical

schematic and connector information.
– Fuse(s)
– Wiring harness
Inspection and Verification – Electrical connector(s)
1. Verify the customer concern. – Horn(s)
2. Visually inspect for obvious signs of electrical – Relay
damage. – Horn switch
– Clock spring
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• The horn does not sound • Fuse(s). • GO to Pinpoint Test A
• Circuit(s).
• Horn(s).
• Horn switch.
• Clock spring.
• Horn relay.
• The horn sounds continuously • Circuit(s). • GO to Pinpoint Test B
• Horn switch.
• Clock spring.
• Horn relay.

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE HORN DOES NOT SOUND
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE OPERATION OF THE HORN RELAY
1 Press the horn switch and listen for the horn
relay clicking.
• Does the horn relay click when the horn switch
is pressed?
→ Yes
GO to A8
→ No
GO to A2
A2: CHECK THE HORN SWITCH OPERATION
1 Disconnect Horn Relay C903.

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413-06-4 Horn 413-06-4

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Press and hold the horn switch.
3 Measure the resistance between horn relay
C903 pin 1, circuit 31S-GJ7 (BK), harness side
and ground.

4 Release the horn switch.

• Is the resistance less than 5 ohms?
→ Yes
GO to A3
→ No
GO to A4
A3: CHECK FOR VOLTAGE AT HORN RELAY
1 Measure the voltage between horn relay C903
pin 2, circuit 30-GJ7 (RD), harness side and
ground; and between the horn relay C903 pin
5, circuit 30-GJ8 (RD), harness side and
ground.

• Are the voltages greater than 10 volts?

→ Yes
CARRY OUT the relay Component Test.
REFER to the wiring diagrams. INSTALL a
new horn relay as necessary. TEST the sys-
tem for normal operation.
→ No
INSTALL a new battery junction box (BJB).
TEST the system for normal operation.
A4: CHECK CIRCUIT 31S-GJ7 (BK/BU) FOR SHORT TO GROUND

WARNING: To deactivate the air bag module, refer to the procedure in Section 501-20B for
the correct air bag module deactivation procedure. Failure to follow this instruction may
result in personal injury.
1 Remove the driver air bag module. REFER to
Section 501-20A / 501-20B.

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413-06-5 Horn 413-06-5

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Clock Spring C413.
3 Measure the resistance between clock spring
C413 pin 4, circuit 31S-GJ7 (BK/BU), harness
side and ground.

• Is the resistance less than 5 ohms?

→ Yes
REPAIR the circuit. TEST the system for
normal operation.
→ No
GO to A5
A5: CHECK THE CLOCK SPRING
1 Disconnect Horn Switch C4.
2 Measure the resistance between horn switch
C4 pin 1, harness side and ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
GO to A6
→ No
INSTALL a new clock spring. REFER to
Section 501-20A / 501-20B. TEST the sys-
tem for normal operation.
A6: CHECK THE HORN SWITCH
1 Disconnect Horn Switch C5.

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413-06-6 Horn 413-06-6

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between horn switch
C5 pin 1, component side and ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
INSTALL a new horn switch. REFER to
Horn Switch in this section. TEST the sys-
tem for normal operation.
→ No
GO to A7
A7: CHECK GROUND CIRCUIT 31-GJ9 (BK)
1 Measure the resistance between clock spring
C413 pin 3, circuit 31-GJ9 (BK), harness side
and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new clock spring. REFER to
Section 501-20A / 501-20B. TEST the sys-
tem for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A8: CHECK THE HORN GROUND CIRCUIT
1 Disconnect Horn Relay C903.

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413-06-7 Horn 413-06-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between horn relay
C903 pin 3, circuit 29S-GJ6 (OG/YE), harness
side and ground.

• Is the resistance between 0.5 and 4 ohms?

→ Yes
GO to A9
→ No
GO to A10
A9: CHECK VOLTAGE AT HORN RELAY
1 Measure the voltage between horn relay C903
pin 5, circuit 30-GJ8 (RD), harness side and
ground.

• Is the voltage greater than 10 volts?

→ Yes
CARRY OUT the relay Component Test.
REFER to the wiring diagrams. INSTALL a
new horn relay as necessary. TEST the sys-
tem for normal operation.
→ No
INSTALL a new battery junction box (BJB).
TEST the system for normal operation.
A10: CHECK CIRCUIT 29S-GJ6 (OG/YE) FOR OPEN
1 Disconnect Horn C151.

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413-06-8 Horn 413-06-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between horn relay
C903 pin 3, circuit 29S-GJ6 (OG/YE), harness
side and the horn C151 pin 2, harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to A11
→ No
REPAIR the circuit. TEST the system for
normal operation.
A11: CHECK THE HORN GROUND CIRCUIT
1 Measure the resistance between horn C151
pin 1, circuit 31-GJ6 (BK), harness side and
ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new horn. TEST the system for
normal operation.
→ No
REPAIR circuit 31-GJ6 (BK). TEST the sys-
tem for normal operation.
PINPOINT TEST B: THE HORN SOUNDS CONTINUOUSLY
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK CIRCUIT 29S-GJ6 (OG/YE) FOR SHORT TO (B+)
1 Disconnect Horn Relay C903.
• Does the horn stop when the relay is discon-
nected?
→ Yes
GO to B2

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413-06-9 Horn 413-06-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR the circuit. TEST the system for
normal operation.
B2: CHECK CIRCUIT 31S-GJ7 (BK)
1 Measure the resistance between horn relay
C903 pin 1, circuit 31S-GJ7 (BK), harness side
and ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
CARRY OUT the relay Component Test.
REFER to the wiring diagrams. INSTALL a
new horn relay as necessary. TEST the sys-
tem for normal operation.
→ No
GO to B3
B3: CHECK CIRCUIT 31S-GJ7 (BK/BU) FOR SHORT TO GROUND

WARNING: To deactivate the air bag module, refer to the procedure in Section 501-20B for
the correct air bag module deactivation procedure. Failure to follow this instruction may
result in personal injury.
1 Remove the driver air bag module. REFER to
Section 501-20A / 501-20B.
2 Disconnect Clock Spring C413.
3 Measure the resistance between horn switch
C413 pin 4, circuit 31S-GJ7 (BK/BU), harness
side and ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
GO to B4
→ No

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413-06-10 Horn 413-06-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the circuit. TEST the system for
normal operation.
B4: CHECK THE CLOCK SPRING
1 Disconnect Horn Switch C4.
2 Measure the resistance between horn switch
C4 pin 1, circuit 31S-GJ9 (BK), component
side and ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
INSTALL a new clock spring. REFER to
Section 501-20A / 501-20B. TEST the sys-
tem for normal operation.
→ No
INSTALL a new horn switch. REFER to
Horn Switch in this section. TEST the sys-
tem for normal operation.

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413-06-11 Horn 413-06-11

REMOVAL AND INSTALLATION

Horn Switch (33 523 0)

REMOVAL AND INSTALLATION

Removal
1. Remove the driver air bag module. For
additional information, refer to Section
501-20A / 501-20B.

Installation
1. To install, reverse the removal procedure.

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413-07-1 Clock 413-07-1

SECTION 413-07 Clock

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Clock ................................................................................................................................. 413-07-2

Inspection and Verification ............................................................................................... 413-07-2
Symptom Chart ................................................................................................................ 413-07-2
Pinpoint Tests .................................................................................................................. 413-07-2

REMOVAL AND INSTALLATION

Clock ............................................................................................................ (33 374 0) 413-07-4

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413-07-2 Clock 413-07-2

DIAGNOSIS AND TESTING

Clock
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 413-06 for Electrical

schematic and connector information.
– Fuse(s)
– Wiring harness
Inspection and Verification – Electrical connector(s)
1. Verify the customer concern. – Clock
2. Visually inspect for obvious signs of electrical 3. If an obvious cause for an observed or
damage. reported concern is found, correct the cause
(if possible) before proceeding to the next
Visual Inspection Chart step.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• The clock operation is er- • Fuse(s). • GO to Pinpoint Test A
ratic/inoperative • Circuit.
• Clock.

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements
PINPOINT TEST A: THE CLOCK OPERATION IS ERRATIC/INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK CIRCUIT 29-GB6 (OG/YE) FOR VOLTAGE
1 Key in OFF position.
2 Disconnect Clock C412.
3 Measure the voltage between clock C412 pin
6, circuit 29-GB6 (OG/YE), harness side and
ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A2
→ No

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413-07-3 Clock 413-07-3

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK fuse F75 (7.5A). INSTALL a new
fuse as required. If the fuse fails again
check for short to ground. REPAIR the cir-
cuit. TEST the system for normal operation.

A2: CHECK CIRCUIT 31-GB6 (BK) FOR OPEN

1 Measure the resistance between C412 pin 3,
circuit 31-GB6 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new clock. REFER to Clock in
this section. TEST the system for normal
operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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413-07-4 Clock 413-07-4

REMOVAL AND INSTALLATION

Clock (33 374 0)

REMOVAL AND INSTALLATION

Removal Vehicles with automatic transaxle

5. Remove the automatic transaxle selector
Vehicles with automatic transaxle
lever trim.
1. Move the automatic transaxle selector
lever to the ""N” position.
All vehicles
2. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
3. Detach the audio unit from the heater
control trim panel.
1. Using audio unit removal tools, gently pull
the removal tools to the left and right of the
audio unit to release the locking tangs.
2. Slide the audio unit out of the heater con-
trol trim panel.

Vehicles with manual transaxle

6. Remove the gearshift lever boot.

4. Remove the audio unit.

• Disconnect the antenna cable and the au-
dio unit electrical connectors.
All vehicles
7. Detach the accessory switches from the
heater control trim panel.

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413-07-5 Clock 413-07-5

REMOVAL AND INSTALLATION (Continued)

8. Remove the heater control trim panel 11. Disconnect the heated front seats electri-
accessory switches. cal connectors.
• Disconnect the electrical connectors.

12. Disconnect the auxiliary climate control

9. Detach the heater control trim panel from electrical connectors.
the instrument panel.
1. Remove the retaining screws.
2. Detach the retaining clips.

13. Remove the clock from the heater control

trim panel.

10. Disconnect the liftgate release switch

electrical connector.

Installation
1. To install, reverse the removal procedure.

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413-07-6 Clock 413-07-6

REMOVAL AND INSTALLATION (Continued)

2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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413-08-1 Information and Message Center 413-08-1

SECTION 413-08 Information and Message Center

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Information and Message Center....................................................................................... 413-08-2

DIAGNOSIS AND TESTING

Information and Message Center....................................................................................... 413-08-3

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413-08-2 Information and Message Center 413-08-2

DESCRIPTION AND OPERATION

Information and Message Center

DESCRIPTION AND OPERATION

For additional information, refer to Section 413-

01.

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413-08-3 Information and Message Center 413-08-3

DIAGNOSIS AND TESTING

Information and Message Center

DIAGNOSIS AND TESTING

1. REFER to Section 413-01.

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413-09-1 Warning Devices 413-09-1

SECTION 413-09 Warning Devices

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Warning Devices ............................................................................................................... 413-09-2

Principles of Operation ..................................................................................................... 413-09-2
Inspection and Verification ............................................................................................... 413-09-2
Symptom Chart ................................................................................................................ 413-09-2
Pinpoint Tests .................................................................................................................. 413-09-2

GENERAL PROCEDURES

Belt Minder Deactivating/Activating ................................................................................... 413-09-5

Preparation....................................................................................................................... 413-09-5
Deactivating/Activating ..................................................................................................... 413-09-5

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413-09-2 Warning Devices 413-09-2

DIAGNOSIS AND TESTING

Warning Devices
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 413-09 for above on the NEXT ignition cycle from OFF or
schematic and connector information. position I to position II.

Principles of Operation Inspection and Verification

Belt Minder 1. Verify the customer concern.
The belt minder feature is a supplemental 2. Visually inspect for obvious signs of
warning that augments the current safety belt mechanical or electrical damage.
warning function. This feature continually reminds
the driver that their safety belt is unbuckled by Visual Inspection Chart
intermittently sounding a chime and illuminating Mechanical Electrical
the safety belt warning indicator in the instrument
– Door ajar switch(es) – Fuse(s)
cluster once the vehicle speed has exceeded 5
mph (7 km/h). – Safety belt buckle – Wiring harness(es)
and pretensioner – Electrical
Immediately after ignition is turned to position II
– Headlamp switch connector(s)
the belt minder is activated. The belt minder
alternates from on for six seconds and off for 30 – Fuel gauge – Switch(es)
seconds until deactivated. – Sensor(s)
The belt minder will be deactivated under the – Generic electronic
following conditions: module (GEM)
• ignition switch is turned to position O 3. If an obvious cause for an observed or
reported concern is found, correct the cause
• ignition switch is turned to position I (if possible) before proceeding to the next
• five minutes has elapsed with the belt minder step.
activated 4. If the cause is not visually evident, verify the
If the customer buckles their safety belt prior to symptom and refer to WDS to diagnose the
belt minder becoming active, belt minder will system.
remain inactive, i.e. will not provide a reminder, 5. If the vehicle is fitted with a belt minder,
until the proper conditions are met as described REFER to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• The belt minder feature does not • Safety belt warning indicator • GO to Pinpoint Test A.
operate correctly switch.
• Circuit(s).
• Restraints control module
(RCM).

Pinpoint Tests
PINPOINT TEST A: THE BELT MINDER FEATURE DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK SAFETY BELT BUCKLE SWITCH FOR CORRECT OPERATION
1 Key in OFF position.
2 Disconnect Safety Belt Buckle Switch C60f.

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413-09-3 Warning Devices 413-09-3

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the safety
belt buckle switch C60f, pin 1 and pin 2, com-
ponent side.

4 Connect the safety belt buckle in to the seat

belt pretensioner.
5 Measure the resistance between the safety
belt buckle switch C60f pin 1 and pin 2, com-
ponent side.
• Does the resistance change from 5 ohms to
10,000 ohms when the safety belt is connected?
→ Yes
GO to A2.
→ No
INSTALL a new safety belt buckle and pre-
tensioner. REFER to Section 501-20A / 501-
20B. TEST the system for normal opera-
tion.
A2: CHECK CIRCUIT 91S-GE52A (BK/RD) FOR OPEN
1 Disconnect RCM C491.
2 Measure the resistance between the RCM
C491 circuit 91S-GE52A, pin 25 (BK/RD), har-
ness side and the safety belt buckle switch
C60f, pin 2, harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to A3.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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413-09-4 Warning Devices 413-09-4

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A3: CHECK CIRCUIT 91-GE52A (BK/RD) FOR GROUND
1 Measure the resistance between the safety
belt buckle switch C60f, circuit 91-GE52A, pin
1 (BK/RD), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
REFER to Section 501-20A / 501-20B.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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413-09-5 Warning Devices 413-09-5

GENERAL PROCEDURES

Belt Minder Deactivating/Activating

GENERAL PROCEDURES

7. The following sequence will confirm the

belt minder is enabled:
Preparation • the safety belt warning indicator flashes
1. Apply the parking brake. four times per second for three seconds.
2. Place gearshift in P (Park) - vehicles with • three seconds with the safety belt warning
automatic transmission or the neutral indicator off.
position - vehicles with manual • the safety belt warning indicator flashes
transmission. four times per second for three seconds
3. Turn the ignition switch to the O position. again.
4. Close all the vehicle doors. 8. The safety belt warning indicator flashing
5. Unbuckle the drivers safety belt. four times per second for three seconds
provides confirmation of belt minder
6. Place the parking lamps/headlamps switch
disabled.
in the OFF position (If vehicle is equipped
with Autolamps, this will not affect the 9. After confirmation, the
procedure). deactivation/activation procedure is
complete.

Deactivating/Activating
1. Turn the ignition switch to position II. (Do
not start the engine).
2. Wait until the safety belt warning indicator
turns off. (Approximately one to two
minutes).
3. NOTE: Steps 3 through 5 must be completed
within 60 seconds or the procedure must be
repeated.
Buckle then unbuckle the safety belt three
times, ending with the safety belt
unbuckled.
4. Turn the 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 indicator will be illuminated for
three seconds.
6. Within seven seconds of the safety belt
warning indicator turning off, buckle then
unbuckle the safety belt. This will enable
the belt minder if disabled or disable belt
minder if enabled.

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414-00-1 Charging System - General Information 414-00-1

SECTION 414-00 Charging System - General

Information
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Charging System ............................................................................................................... 414-00-2

Inspection and Verification ............................................................................................... 414-00-2

GENERAL PROCEDURES

Battery Charging........................................................................................... (31 003 0) 414-00-3

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414-00-2 Charging System - General Information 414-00-2

DIAGNOSIS AND TESTING

Charging System
DIAGNOSIS AND TESTING

Inspection and Verification

WARNING: Batteries contain sulphuric
acid. Avoid contact with skin, eyes, or
clothing. Also, shield your eyes when
working near batteries to protect against
possible splashing of the acid solution.
In case of acid contact with skin or eyes,
flush immediately with water for a
minimum of 15 minutes and get prompt
medical attention. If acid is swallowed,
call a physician immediately. Failure to
follow these instructions may result in
personal injury.
WARNING: Batteries normally produce
explosive gases which can cause
personal injury. Therefore, do not allow
flames, sparks or lighted substances to
come near the battery. When charging or
working near a battery, always shield
your face and protect your eyes. Always
provide ventilation. Failure to follow
these instructions may result in personal
injury.
1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Accessory drive belt – Fuse(s)
– Generator – Wiring harness
– Electrical
connector(s)
– Battery junction box
(BJB)
– Battery
– Battery cables
– Charging system
warning indicator
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

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414-00-3 Charging System - General Information 414-00-3

GENERAL PROCEDURES

Battery Charging (31 003 0)

GENERAL PROCEDURES

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414-00-4 Charging System - General Information 414-00-4

GENERAL PROCEDURES

1. WARNING: Keep batteries out of reach

of children. Batteries contain
sulphuric acid, avoid contact with
skin, eyes or clothing. Shield your
eyes when working near the battery to
protect against possible splashing of
the acid solution. In case of acid
contact with the skin or the eyes, flush
immediately with water for a minimum
of 15 minutes and seek prompt
medical attention. If acid is swallowed,
call a physician immediately. Failure
to follow these instructions may result
in personal injury.
WARNING: Batteries normally produce WARNING: It is important not to overfill a
explosive gases which can cause battery, as this can cause acid leakage
personal injury, therefore do not allow and corrosion damage to the vehicle.
flames, sparks or lighted substances to Failure to follow this instruction may
come near the battery. When charging or result in personal injury.
working near the battery always shield 2. If the level is below the maximum mark,
your face and protect your eyes. Always remove the vent covers and top up the
provide adequate ventilation. Failure to cell(s) to the correct level.
follow these instructions may result in 3. Cold batteries will not readily accept a
personal injury. charge. Therefore batteries should be
allowed to warm up to approximately 5°C.
WARNING: Always observe all
(41°F.) before charging. This may require
manufacturers instructions when using
four to eight hours at room temperature
any charging equipment. Failure to
depending on the initial temperature and
follow this instruction may result in
the battery size.
personal injury.
4. A battery which has been completely
WARNING: Connect the charger to the discharged may be slow to accept a
battery before switching the charger on. charge initially, and in some cases may
Failure to follow this instruction may not accept a charge at the normal charger
result in personal injury. setting. When batteries are in this
condition, charging can be started by use
WARNING: Switch the charger off before of the dead battery switch on chargers that
disconnecting the charger from the have this facility equipped.
battery. Failure to follow this instruction
5. To determine whether a battery is
may result in personal injury.
accepting a charge, follow the
CAUTION: Batteries should not be manufacturer's instructions for the
charged in the vehicle. charger, for use of the dead battery switch.
If the switch is the spring-loaded type, it
CAUTION: Do not rely on the generator to should be held in the ON position for up to
recharge a discharged battery as it three minutes.
would take in excess of eight hours of 6. After releasing the dead battery switch and
continuous driving with no additional with the charger still on, measure the
loads placed on the charging system. battery voltage. If it shows 12 volts or
NOTE: The maximum level mark is higher, the battery is accepting a charge
approximately 40mm below the top of the battery. and is capable of being recharged.
Place the battery on a level surface and However, it may require up to two hour of
check the electrolyte level through the cas- charging with batteries colder than 5°C
ing, reaches the indicated maximum mark. (41°F) before the charge rate is high
enough to show a charge on an ammeter.
It has been found that all non-damaged
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414-00-5 Charging System - General Information 414-00-5

GENERAL PROCEDURES (Continued)

batteries can be charged by this

procedure. If a battery cannot be charged
by this procedure, a new one should be
installed.
7. A rapid recharger procedure has been
developed for recharging batteries that
have passed the Load Test and only need
a recharge. This can be due to in-service
no-start battery failures (vehicle will not
crank due to low battery state of charge) or
battery discharged in vehicle due to key-
off loads.
8. With the cables then disconnected, the
battery can be rapidly recharged by using
either of the following methods:
• Carry out a two hour charge using 20A
constant current (manual setting on
charger).
• Carry out a two hour charge using a
constant potential (automatic setting on
charger).

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414-01-1 Battery, Mounting and Cables 414-01-1

SECTION 414-01 Battery, Mounting and Cables

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 414-01-2

DIAGNOSIS AND TESTING

Battery............................................................................................................................... 414-01-3
Inspection and Verification ............................................................................................... 414-01-3
Symptom Chart ................................................................................................................ 414-01-3

GENERAL PROCEDURES

Battery Disconnect ............................................................................................................ 414-01-4

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414-01-2 Battery, Mounting and Cables 414-01-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Battery hold down clamp retaining nuts 6 - 53
Battery terminal clamp retaining nut 6 - 53
Battery junction box (BJB) electrical connector re- 7 - 62
taining nut
Generator electrical connector retaining nut 8 - 71
Ignition switch to starter motor cable retaining nut 8 - 71
Starter motor positive cable retaining nut 12 9 -

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414-01-3 Battery, Mounting and Cables 414-01-3

DIAGNOSIS AND TESTING

Battery
DIAGNOSIS AND TESTING

WARNING: Batteries normally produce

explosive gases which can cause
General Equipment personal injury. Therefore, do not allow
flames, sparks or lighted substances to
Battery Tester come near the battery. When charging or
working near a battery, always shield
your face and protect your eyes. Always
Inspection and Verification provide adequate ventilation. Failure to
follow these instructions may result in
WARNING: Batteries contain sulphuric personal injury.
acid. Avoid contact with skin, eyes, or 1. Verify the customer concern.
clothing. Also, shield your eyes when
2. Visually inspect for obvious signs of electrical
working near batteries to protect against
damage.
possible splashing of the acid solution.
In case of acid contact with skin or eyes,
flush immediately with water for a Inspection and Verification
minimum of 15 minutes and get prompt Electrical
medical attention. If acid is swallowed, • Electrical connector(s)
call a physician immediately. Failure to • Battery terminal clamps
follow these instructions may result in
personal injury. • Battery cable(s)
• Battery
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.
Symptom Chart

Condition Possible Sources Action

• Vehicle electrical systems inop- • Battery. • CARRY OUT a battery condition
erative test, using the battery tester.
• The engine cranks slowly • Battery. • CARRY OUT a battery condition
test, using the battery tester.
• Battery cable(s). • REFER to Section 303-06.
• Starter motor.

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414-01-4 Battery, Mounting and Cables 414-01-4

GENERAL PROCEDURES

Battery Disconnect
GENERAL PROCEDURES

2. Disconnect the battery ground cable.

Disconnect
Connect
WARNING: Batteries normally produce
explosive gases which may cause WARNING: Batteries normally produce
personal injury, therefore do not allow explosive gases which may cause
flames, sparks or lighted substances to personal injury, therefore do not allow
come near the battery. When charging or flames, sparks or lighted substances to
working near the battery always shield come near the battery. When charging or
your face and protect your eyes. Always working near the battery always shield
provide adequate ventilation. Failure to your face and protect your eyes. Always
follow these instructions may result in provide adequate ventilation. Failure to
personal injury. follow these instructions may result in
personal injury.
WARNING: Batteries contain sulphuric
acid, avoid contact with skin eyes or WARNING: Batteries contain sulphuric
clothing. Shield your eyes when working acid, avoid contact with skin eyes or
near the battery to protect against clothing. Shield your eyes when working
possible splashing of the acid solution. near the battery to protect against
In case of acid contact with the skin or possible splashing of the acid solution.
eyes, flush immediately for a minimum of In case of acid contact with the skin or
15 minutes and seek prompt medical eyes, flush immediately for a minimum of
attention. If swallowed, call a physician 15 minutes and seek prompt medical
immediately. Failure to follow these attention. If swallowed, call a physician
instructions may result in personal immediately. Failure to follow these
injury. instructions may result in personal
injury.
WARNING: Audio unit key code saving
devices must not be used when working CAUTION: Make sure all electrical
on supplemental restraint or fuel systems are switched OFF before
systems. When using these devices the connecting the battery ground cable to
vehicle electrical system is still live but avoid damage to the vehicle electrical
with a reduced current flow. Failure to system.
follow this instruction may result in 1. Connect the battery ground cable.
personal injury.
2. Enter the audio unit keycode and preset
CAUTION: Make sure the engine is not radio frequencies.
running before disconnecting the battery 3. Reset the clock to the correct time.
ground cable to avoid damage to the 4. NOTE: When the battery has been
vehicle electrical system. disconnected and connected, the stored idle
NOTE: Before disconnecting the battery make and drive values contained within the
sure that no data is required from the powertrain powertrain control module (PCM) will have
control module (PCM), as battery cable been erased. The following steps must be
disconnection will erase any fault codes and carried out to allow the PCM to relearn its idle
idle/drive values held in the keep alive memory and drive values.
(KAM). It is not necessary to disconnect or Start and run the engine at idle for three
remove electronic control modules. minutes.
NOTE: This procedure should be used to 5. When the engine reaches normal operating
disconnect the battery while carrying out repairs temperature, increase the engine speed to
that refer to the battery being disconnected. 1200 rpm and maintain for approximately
1. Obtain and record the audio unit keycode two minutes.
and preset radio frequencies.

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414-01-5 Battery, Mounting and Cables 414-01-5

GENERAL PROCEDURES (Continued)

6. Drive the vehicle for approximately five

miles/eight kilometers of varied driving.

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414-02-1 Generator and Regulator 414-02-1

SECTION 414-02 Generator and Regulator

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 414-02-2

DESCRIPTION AND OPERATION

Generator .......................................................................................................................... 414-02-3

DIAGNOSIS AND TESTING

Generator .......................................................................................................................... 414-02-5

REMOVAL AND INSTALLATION

Generator — 1.8L/2.0L................................................................................. (31 414 0) 414-02-6

Generator — 2.5L/3.0L................................................................................. (31 414 0) 414-02-11

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414-02-2 Generator and Regulator 414-02-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Generator retaining bolts 47 35 -
Generator electrical connector retaining nut 8 - 71
Tie-rod end retaining nut 40 30 -
Generator mounting studs - vehicles with 2.0L die- 15 11 -
sel engine
Generator retaining nuts - vehicles with 2.0L diesel 47 35 -
engine
Generator cooling duct retaining nuts 4 - 35

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414-02-3 Generator and Regulator 414-02-3

DESCRIPTION AND OPERATION

Generator
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
2 - Generator cooling duct - ve-
1 - Generator retaining bolts hicles with 1.8L or 2.0L en-
gine shown, vehicles with
2.0L diesel engine or 2.5L
engine similar

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414-02-4 Generator and Regulator 414-02-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description
Number
3 - Generator - vehicles with
1.8L or 2.0L engine shown,
vehicles with 2.0L diesel en-
gine or 2.5L engine similar
4 - Generator Decoupler - vehi-
cles with 1.8L or 2.0L engine
with manual transaxle

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414-02-5 Generator and Regulator 414-02-5

DIAGNOSIS AND TESTING

Generator
DIAGNOSIS AND TESTING

REFER to Section 414-00.

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414-02-6 Generator and Regulator 414-02-6

REMOVAL AND INSTALLATION

Generator — 1.8L/2.0L (31 414 0)

REMOVAL AND INSTALLATION

5. Detach the accessory drive belt.

1. Rotate the accessory drive belt tensioner
Special Tool(s) clockwise.
2. Detach the accessory drive belt from the
Separator, Ball Joint generator pulley.
211-020 (13-006)

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the generator upper retaining bolt.
• Remove the wiring harness support
bracket from the generator upper retaining
bolt. 6. Remove the generator cooling duct intake
pipe.
1. Detach the generator cooling duct intake
pipe retaining clip.
2. Release the clips and remove the
generator cooling duct intake pipe.
• Remove and discard the generator cooling
duct intake pipe retaining clip.

3. Raise and support the vehicle. For

additional information, refer to Section
100-02.
4. Remove the splash shield.

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414-02-7 Generator and Regulator 414-02-7

REMOVAL AND INSTALLATION (Continued)

7. Disconnect the generator electrical con- 11. CAUTION: Protect the ball joint seal
nectors. using a soft cloth to prevent damage.
Using the special tool, detach the tie-rod
end from the wheel knuckle.
• Remove and discard the tie-rod end retain-
ing nut.

8. Remove the right-hand front wheel and

tire. For additional information, refer to
Section 204-04.
9. Remove the steering gear gaiter shield.
12. Remove the generator lower retaining
bolts.
• Remove the wiring harness support
bracket from the generator lower retaining
bolt.

10. CAUTION: Leave the tie-rod end

retaining nut in place to protect the
ball joint stud.
Loosen the tie-rod end retaining nut.

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414-02-8 Generator and Regulator 414-02-8

REMOVAL AND INSTALLATION (Continued)

13. Remove the generator through the 2. Install the generator through the wheel-
wheelhousing. housing.

14. Remove the generator cooling duct from 3. NOTE: Make sure the wiring harness support
the generator. bracket is installed.
NOTE: Do not tighten the generator lower
retaining bolts at this stage.
Install the generator lower retaining bolts.

Installation
1. Install the generator cooling duct to the 4. Lower the vehicle.
generator.
5. NOTE: Make sure the wiring harness support
bracket is installed.
Install the generator upper retaining bolt.

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414-02-9 Generator and Regulator 414-02-9

REMOVAL AND INSTALLATION (Continued)

6. Raise the vehicle.

10. Install the right-hand front wheel and tire.
7. Tighten the generator lower retaining For additional information, refer to
bolts. Section 204-04.
1. Tighten the right-hand lower retaining bolt. 11. Connect the generator electrical connec-
2. Tighten the left-hand lower retaining bolt. tors.

8. WARNING: Install a new tie-rod end 12. NOTE: Install a new generator cooling duct
retaining nut. Failure to follow this intake pipe retaining clip.
instruction may result in personal Install the generator cooling duct intake
injury. pipe.
Attach the tie-rod end to the wheel knuckle 1. Install the generator cooling duct intake
and install the tie-rod end retaining nut. pipe retaining clip.
2. Connect the generator cooling duct intake
pipe to the generator cooling duct.
• Attach the generator cooling duct intake
pipe retaining clip.

9. Install the steering gear gaiter shield.

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414-02-10 Generator and Regulator 414-02-10

REMOVAL AND INSTALLATION (Continued)

13. Install the accessory drive belt.
1. Rotate the accessory drive belt tensioner
clockwise.
2. Install the accessory drive belt to the gen-
erator pulley.

14. Install the splash shield.

15. Lower the vehicle.

16. Connect the battery ground cable. For
additional information, refer to Section
414-01.
17. Initialize the door window motors. For
additional information, refer to Section
501-11.

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414-02-11 Generator and Regulator 414-02-11

REMOVAL AND INSTALLATION

Generator — 2.5L/3.0L (31 414 0)

5. Remove the steering gear gaiter shield.

Special Tool(s)
Separator, Ball Joint
211-020 (13-006)

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the right-hand front wheel and 6. CAUTION: Leave the tie-rod end
tire. For additional information, refer to retaining nut in place to protect the
Section 204-04. ball joint stud.
3. Remove the splash shield.
Loosen the tie-rod end retaining nut.

4. Detach the accessory drive belt.

1. Rotate the accessory drive belt tensioner
clockwise.
2. Detach the accessory drive belt from the
generator pulley.

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414-02-12 Generator and Regulator 414-02-12

REMOVAL AND INSTALLATION (Continued)

7. CAUTION: Protect the ball joint seal 10. Detach the generator wiring harness from
using a soft cloth to prevent damage. the top of the generator.
Using the special tool, detach the tie-rod
end from the wheel knuckle.
• Remove and discard the tie-rod end retain-
ing nut.

11. Remove the generator through the

wheelhousing.

8. Disconnect the generator electrical con-

nectors.

12. Remove the generator cooling duct from

the generator.

9. Detach the generator from the engine.

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414-02-13 Generator and Regulator 414-02-13

REMOVAL AND INSTALLATION (Continued)

Installation
1. WARNING: Install a new tie-rod end
retaining nut. Failure to follow this
instruction may result in personal
injury.
CAUTION: Loosely install the generator
retaining bolts before tightening them.
To install, reverse the removal procedure.
• Tighten the generator retaining bolts in the
sequence shown.

2. Initialize the door window motors. For

additional information, refer to Section
501-11.

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415-00-1 Entertainment System - General Information 415-00-1

SECTION 415-00 Entertainment System - General

Information
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Audio System .................................................................................................................... 415-00-2

Principles of Operation ..................................................................................................... 415-00-2
Inspection and Verification ............................................................................................... 415-00-2
Self-Diagnostic Mode ....................................................................................................... 415-00-3
Symptom Chart ................................................................................................................ 415-00-4
Pinpoint Tests .................................................................................................................. 415-00-6
Component Tests ............................................................................................................. 415-00-36

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415-00-2 Entertainment System - General Information 415-00-2

DIAGNOSIS AND TESTING

Audio System
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 415-01 for Mechanical Electrical

schematic and connector information.
– Audio unit – Fuse(s)
General Equipment – Antenna(s) – Wiring harness
– Cassette player – Electrical
Worldwide Diagnostic System (WDS) (418- connector(s)
– Compact disc (CD)
F224).
player jammed, not – Audio unit
loading – CD player
– Foreign objects – Steering wheel
Principles of Operation contacting speaker audio controls (if
Diversity Antenna – Trim poorly equipped)
The audio unit has the facility to receive the input fitted/resonance – Antenna(s)
of two antennae. Sensors within the audio unit – Steering wheel – Remote control
calculate which of the antenna signals is the audio controls (if battery(s)
strongest and uses this signal to improve the equipped)
– Remote control
reception for the listener. The first antenna is the – Video cassette
original vehicle antenna fitted on the roof at the – Video display
player jammed, not
front of the vehicle. loading – Video cassette
player
The second antenna is integrated into the rear – Contaminated video
window glass on all vehicles except wagon. On cassette player – Video system
the wagon the second antenna is integrated into heads module
the right-hand rear quarter window glass. It is – Diversity antenna – Passenger
connected to the audio unit by a cable. grid wires entertainment
control panel
– External
Inspection and Verification game/media source
(games con-
1. Verify the customer concern.
sole/video camera
2. Visually inspect for obvious signs of etc)
mechanical or electrical damage.
3. If an obvious cause for an observed or
reported concern is found, correct the cause
Visual Inspection Chart
(if possible) before proceeding to the next
step.
4. If an obvious cause is not found, codes may
be shown in the audio unit display (vehicles
with 6000, 6006E or 9006 audio unit only).
Check the audio unit display for the following
Error Codes:
• for vehicles with 6006E or 9006 audio unit
refer to the CD Error Codes - vehicles with
Vehicles with 6006E or 9006 Audio Unit
• for vehicles with 6000 audio unit refer to the
CD Error Codes - vehicles with 6000 Audio
Unit
• for vehicles with CD changer refer to the CD
Error Codes - vehicles with CD Changer
5. If no error codes are displayed on the audio
unit refer to the Self-Diagnostic Mode.
CD Error Codes - vehicles with 6006E or 9006 Audio Unit

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415-00-3 Entertainment System - General Information 415-00-3

DIAGNOSIS AND TESTING

Error Codes
Error Code Error Description Error Rectification
E1 Communications Er- Install a new audio unit. TEST the system for normal operation.
ror
E2 Overtemp Error The Audio unit is too hot, unit will not work until it has cooled down.
Check the heater duct(s) are not bleeding hot air on to the radio. If
the concern persists, INSTALL a new audio unit. TEST the system
for normal operation.
E3 Mechanical Error Install a new audio unit. TEST the system for normal operation.
E4 Focus Error CD is upside down or dirty. Clean the CD and try it again, if the er-
ror code is still displayed, INSERT a different CD. If the error code
is still displayed. INSTALL a new audio unit. TEST the system for
normal operation.
E5 Overcurrent Error Install a new audio unit. TEST the system for normal operation.
CD Error Codes - vehicles with 6000 Audio Unit

Error Codes
Error Code Error Description Error Rectification
E11 SPI Bus Failure CHECK and REPAIR the wiring harness. If the wiring harness is
OK, INSTALL a new audio unit. TEST the system for normal op-
eration.
E12 Communications Er- Install a new audio unit. TEST the system for normal operation.
ror
E14 Overtemp Error The Audio unit is too hot, unit will not work until it has cooled down.
Check the heater duct(s) are not bleeding hot air on to the radio. If
the concern persists, INSTALL a new audio unit. TEST the system
for normal operation.
E15 Mechanical Error Install a new audio unit. TEST the system for normal operation.
E16 CD Eject Failure Install a new audio unit. TEST the system for normal operation.
CD Error Codes - vehicles with CD Changer

Error Codes
Error Code Error Description Error Rectification
E2 Communications Er- Install a new CD changer. TEST the system for normal operation.
ror
E3 Focus Error CD is upside down or dirty. Clean the CD and try it again, if the er-
ror code is still displayed, INSERT a different CD. If the error code
is still displayed. INSTALL a new CD changer. TEST the system
for normal operation.
E4 Overtemp Error The CD changer is too hot, unit will not work until it has cooled
down. Check the heater duct(s) are not bleeding hot air on to the
CD changer. If the concern persists, INSTALL a new CD changer.
TEST the system for normal operation.
E5 Mechanical Error Install a new CD changer. TEST the system for normal operation.
preset buttons 3 and 6 together until the
audio unit enters the Self-Diagnostic Mode.
Self-Diagnostic Mode
1. To enter the audio unit Self-Diagnostic Mode,
switch the audio unit ON. Press and hold the

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415-00-4 Entertainment System - General Information 415-00-4

DIAGNOSIS AND TESTING

Self-Diagnostic Mode
Test Message Displayed Circuit Tested Description
1. FM waveband check. FM frequency received. Antenna signal. Tests signal from the an-
tenna cable.
2. Traffic Announce- TP. Traffic announcement Tests the volume of TA.
ment. volume level.
3.Test speaker circuit 4CH LF for four channel Left hand front speaker Test speaker circuit.
left hand front speaker. system 2CH LF for two circuit.
channel system.
4.Test speaker circuit 4CH RF for four channel Right hand front speaker Test speaker circuit.
right hand front speaker. system 2CH RF for two circuit.
channel system.
5.Test speaker circuit 4CH LR for four channel Left hand rear speaker Test speaker circuit.
left hand rear speaker. system. circuit.
6.Test speaker circuit 4CH RR for four channel Right hand rear speaker Test speaker circuit.
right hand rear speaker. system. circuit.
7. Test communications CDDJ OK/CD OK if Compact disc communi- Test compact disc cir-
with compact disc auto- communications are cations circuit. cuit.
changer (if equipped) or achieved and NO
internal CD changer. CDDJ/NO CD if no
communications are
achieved.
2. If the cause is not visually evident, verify the
symptom and refer to the following Symptom
Chart.
Symptom Chart

Condition Possible Sources Action

• The audio unit is inopera- • Fuse(s). • GO to Pinpoint Test A.
tive/does not operate correctly • Circuit.
• Audio unit.
• The display is blank - radio and • Audio unit. • INSTALL a new audio unit.
cassette player operate
• Poor reception • Antenna. • GO to Pinpoint Test B.
• Antenna cable.
• Audio unit.
• Diversity antenna. • GO to Pinpoint Test B.
• Diversity antenna cable.
• Audio unit.
• Poor quality/distorted sound • Speaker(s). • GO to Pinpoint Test C.
from one or more speakers (not • Circuit.
all speakers) • Audio unit.
• No sound from all speakers • Speaker(s). • GO to Pinpoint Test D.
• Circuit.
• Audio unit.
• No sound from one or more of • Speaker(s). • GO to Pinpoint Test E.
the speakers (not all speakers) • Circuit.
• Audio unit.

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415-00-5 Entertainment System - General Information 415-00-5

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• The auxiliary audio control is • Circuit. • GO to Pinpoint Test F.
inoperative/does not operate • Audio control switch.
correctly. • Audio unit.
• The video system is inopera- • Remote control. • CHECK the remote control bat-
tive/does not operate correctly • Remote control batteries. teries for correct voltage. If the
remote control batteries are not
to correct specification. Install
new batteries to the remote con-
trol. TEST the system for normal
operation.
• Circuit(s). • GO to Pinpoint Test G.
• Video system module.
• Audio unit.
• Video cassette player. • GO to Pinpoint Test J.
• No auxiliary headphone audio • Contaminated video cassette • CLEAN the video cassette
player heads. player heads using a cleaning
cassette.
• Headphone(s). • GO to Pinpoint Test H.
• Circuit(s).
• Passenger entertainment control
panel.
• Video system module.
• Video cassette player. • GO to Pinpoint Test J.
• External game/media source • Not Ford responsibility. REFER
(games console/video camera the customer to the game/media
etc). source supplier.
• The video display is inopera- • Contaminated video cassette • CLEAN the video cassette
tive/does not operate correctly player heads. player heads using a cleaning
cassette.
• Circuit(s). • GO to Pinpoint Test I.
• Video display.
• Video system module.
• Video cassette player. • GO to Pinpoint Test J.
• External game/media source • Not Ford responsibility. REFER
(games console/video camera the customer to the game/media
etc). source supplier.
• The video cassette player is in- • Contaminated video cassette • CLEAN the video cassette
operative/does not operate cor- player heads. player heads using a cleaning
rectly cassette.
• Circuit(s). • GO to Pinpoint Test J.
• Video cassette player.
• Audio unit.
• The remote control is inopera- • Remote control. • GO to Pinpoint Test K.
tive/does not operate correctly • Circuit(s).
• Video display infrared sensor.
• Video system module.

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415-00-6 Entertainment System - General Information 415-00-6

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• External game console/media • External game/media source • Not Ford responsibility. REFER
source is inoperative/does not (games console/video camera the customer to the game/media
operate correctly etc). source supplier.
• Inverter cable. • Not Ford responsibility. REFER
the customer to the inverter ca-
ble supplier.
• Circuit(s). • GO to Pinpoint Test L.
• Passenger entertainment control
panel.
• Video system module.
• No video cassette player on- • Video cassette player. • INSTALL a new video cassette
screen menu options display player.
• CD changer is inoperative/does • Circuit(s). • GO to Pinpoint Test M.
not operate correctly • Fuse.
• CD changer.
• Audio unit.

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR VOLTAGE TO AUDIO UNIT
1 Disconnect Audio Unit C483.
2 Key in ACCESSORY position.
3 Measure the voltage between the audio unit
C483 pin 1, circuit 29-MD15 (OG/BK), harness
side and ground, and between the audio unit
C483 pin 3, circuit 75-MD15 (YE/GN), harness
side and ground.

• Are the voltages greater than 10 volts?

→ Yes
GO to A2.
→ No
REPAIR circuit 29-MD15 (OG/BK) or circuit
75-MD15 (YE/GN). TEST the system for
normal operation.

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415-00-7 Entertainment System - General Information 415-00-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A2: CHECK THE AUDIO UNIT GROUND CIRCUITS FOR OPEN
1 Key in OFF position.
2 Measure the resistance between the audio unit
C483 pin 6, circuit 91-MD15 (BK/GN), harness
side and ground, and between the audio unit
C483 pin 2, circuit 91-MD34 (BK/YE), harness
side and ground.

• Are the resistances less than 5 ohms?

→ Yes
INSTALL a new audio unit. TEST the sys-
tem for normal operation.
→ No
REPAIR circuit 91-MD15 (BK/GN) or 91-
MD34 (BK/YE). TEST the system for normal
operation.
PINPOINT TEST B: POOR RECEPTION
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE ANTENNA CABLE SHIELD
1 Key in OFF position.
2 Disconnect the antenna cable from the audio
unit.
3 Measure the resistance between the antenna
cable ground connector (shield), and ground.

• Is the resistance less than 0.1 ohm?

→ Yes
GO to B2.
→ No

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415-00-8 Entertainment System - General Information 415-00-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CLEAN and TIGHTEN the antenna base
connection to the body. If the concern per-
sists, INSTALL a new antenna cable. TEST
the system for normal operation.
B2: CHECK THE ANTENNA CENTER CONDUCTOR FOR OPEN
1 Remove the antenna mast.
2 Measure the resistance of the center conductor
between the ends of the antenna cable.

• Is the resistance less than 0.1 ohm?

→ Yes
GO to B3.
→ No
INSTALL a new antenna cable. TEST the
system for normal operation.
B3: CHECK ANTENNA CABLE FOR SHORT
1 Measure the resistance between the antenna
center conductor and the antenna ground
(shield).

• Is the resistance greater than 10,000 ohms?

→ Yes
If a diversity antenna is fitted to the vehicle.
GO to B4.
CLEAN and TIGHTEN the ground connec-
tions at the base of the antenna and battery
negative cable to the body. If concern the
persists, INSTALL a new audio unit. TEST
the system for normal operation.
→ No

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415-00-9 Entertainment System - General Information 415-00-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new antenna cable. TEST the
system for normal operation.
B4: CHECK THE DIVERSITY ANTENNA GRID WIRES ON THE REAR WINDOW GLASS OR
RIGHT-HAND REAR QUARTER WINDOW GLASS
1 Check the diversity antenna grid wires on the
rear window glass or right-hand rear quarter
window glass for damage.
• Are the diversity antenna grid wires on the rear
window glass or right-hand rear window glass
damaged?
→ Yes
On all vehicles except wagon. INSTALL a
new rear window glass. REFER to Rear
Window Glass - 4-Door /
Rear Window Glass - 5-Door in this section.
TEST the system for normal operation.
Wagon. INSTALL a new right-hand rear
quarter window glass. REFER to Rear
Quarter Wnidow Glass - Wagon in this sec-
tion. TEST the system for normal operation.
→ No
GO to B5.
B5: CHECK THE DIVERSITY ANTENNA CABLE SHIELD
1 Key in OFF position.
2 Disconnect the diversity antenna cable from
the audio unit.
3 Measure the resistance between the diversity
antenna cable ground connector (shield), and
ground.

• Is the resistance less than 0.1 ohm?

→ Yes
GO to B6.
→ No
INSTALL a new diversity antenna cable.
TEST the system for normal operation.
B6: CHECK THE DIVERSITY ANTENNA FOR OPEN
1 Remove the diversity antenna mast.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance of the diversity an-
tenna rear window glass connector and the di-
versity antenna cable audio unit connector.

• Is the resistance less than 0.1 ohm?

→ Yes
GO to B7.
→ No
INSTALL a new diversity antenna cable.
TEST the system for normal operation.
B7: CHECK DIVERSITY ANTENNA CABLE FOR SHORT
1 Measure the resistance between the diversity
antenna center conductor and the diversity an-
tenna ground (shield).

• Is the resistance greater than 10,000 ohms?

→ Yes
INSTALL a new audio unit. TEST the sys-
tem for normal operation.
→ No
INSTALL a new diversity antenna cable.
TEST the system for normal operation.
PINPOINT TEST C: POOR QUALITY/DISTORTED SOUND FROM ONE OR MORE SPEAKERS
(NOT ALL SPEAKERS)
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the inopera-
tive speaker pin 1 and pin 2, component side.

• Is the resistance approximately 4.0 ohms?

→ Yes
GO to C2.
→ No
INSTALL a new speaker. TEST the system
for normal operation.
C2: CHECK SPEAKER INPUT FOR SHORT TO GROUND
1 Disconnect Audio Unit C484.
2 Measure the resistance between the inopera-
tive speaker connector pin 1, harness side and
ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
GO to C3.
→ No
REPAIR speaker input circuit. TEST the
system for normal operation.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C3: CHECK SPEAKER RETURN FOR SHORT TO GROUND
1 Measure the resistance between the inopera-
tive speaker connector pin 2, harness side and
ground.

• Is the resistance greater than 10,000 ohms?

→ Yes
INSTALL a new speaker. TEST the system
for normal operation. If the concern persists,
INSTALL a new audio unit. TEST the sys-
tem for normal operation.
→ No
REPAIR speaker return circuit. TEST the
system for normal operation.
PINPOINT TEST D: NO SOUND FROM ALL SPEAKERS
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK SPEAKER INPUT CIRCUIT FOR SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Audio Unit C484.
3 Measure the resistance between the following
audio unit connector pins and ground:
- (Front left speaker) C484 pin 1, circuit 8-
MD10 (WH/BK), harness side and ground.
- (Rear left speaker) C484 pin 3, circuit 8-
MD11 (WH/VT), harness side and ground.
- (Front right speaker) C484 pin 5, circuit 8-
MD17 (WH/RD), harness side and ground.
- (Rear right speaker) C484 pin 7, circuit 8-
MD18 (WH), harness side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
GO to D2.
→ No
REPAIR the circuit in question. TEST the
system for normal operation.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
D2: CHECK SPEAKER RETURN CIRCUIT FOR SHORT TO GROUND
1 Measure the resistance between the following
audio unit connector pins and ground:
- (Front left speaker) C484 pin 2, circuit 10-
MD10 (GY/BK), harness side and ground.
- (Rear left speaker) C484 pin 4, circuit 10-
MD11 (GY/WH), harness side and ground.
- (Front right speaker) C484 pin 6, circuit 10-
MD17 (GY/RD), harness side and ground.
- (Rear right speaker) C484 pin 8, circuit 10-
MD18 (GY), harness side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
INSTALL a new audio unit. TEST the sys-
tem for normal operation.
→ No
REPAIR the circuit in question. TEST the
system for normal operation.
PINPOINT TEST E: NO SOUND FROM ONE OR MORE OF THE SPEAKERS (NOT ALL
SPEAKERS)
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inopera-
tive speaker pin 1 and pin 2, component side.

• Is the resistance approximately 4.0 ohms?

→ Yes
GO to E2.
→ No
INSTALL a new speaker(s). TEST the sys-
tem for normal operation.
E2: CHECK SPEAKER CIRCUIT RESISTANCE - SPEAKER DISCONNECTED
1 Disconnect Audio Unit C484.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the audio unit
C484 and the speaker connector pins for the
inoperative speaker(s).
- (Front left speaker) C484 pin 1, circuit 8-
MD10 (WH/BK), harness side and C720 pin
2, circuit 8-MD28 (WH), harness side.
- (Front left speaker) C484 pin 2, circuit 10-
MD10 (GY/BK), harness side and C720 pin 1,
circuit 10-MD28 (GY), harness side.
- (Front right speaker) C484 pin 5, circuit 8-
MD17 (WH/RD), harness side and C723 pin
2, circuit 8-MD28 (WH), harness side.
- (Front right speaker) C484 pin 6, circuit 10-
MD17 (GY/RD), harness side and C723 pin 1,
circuit 10-MD28 (GY), harness side.
- (Rear left speaker) C484 pin 3, circuit 8-
MD11 (WH/VT), harness side and C722 pin
2, circuit 8-MD29 (WH/VT), harness side.
- (Rear left speaker) C484 pin 4, circuit 10-
MD11 (GY/WH), harness side and C722 pin
1, circuit 10-MD29 (GY/WH), harness side.
- (Rear right speaker) C484 pin 7, circuit 8-
MD18 (WH), harness side and C724 pin 2,
circuit 8-MD29 (WH/VT), harness side.
- (Rear right speaker) C484 pin 8, circuit 10-
MD18 (GY), harness side and C724 pin 1,
circuit 10-MD29 (GY/WH), harness side.
• Is the resistance less than 5 ohms?
→ Yes
INSTALL a new speaker. TEST the system
for normal operation. If concern persists,
INSTALL a new audio unit. TEST the sys-
tem for normal operation
→ No
REPAIR the circuit in question. TEST the
system for normal operation.
PINPOINT TEST F: THE AUXILIARY AUDIO CONTROL SWITCH IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK THE AUDIO UNIT OPERATES CORRECTLY WITHOUT USING THE AUDIO
CONTROL SWITCH
1 Operate the audio unit without the audio con-
trol switch.
• Does the audio unit operate correctly without
using the remote control?
→ Yes
GO to F2.
→ No
INSTALL a new audio unit. TEST the sys-
tem for normal operation.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
F2: CHECK THE CIRCUIT 8-MD26 FOR OPEN
1 Disconnect Audio Unit C485.
2 Disconnect Audio Control Switch C487.
3 Measure the resistance between the audio unit
C485 pin 11, circuit 8-MD26 (WH/BK) harness
side and the audio control switch C487 pin 1,
circuit 8-MD26 (WH/BK) harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to F3.
→ No
REPAIR the circuit. TEST the system for
normal operation.
F3: CHECK CIRCUIT 9-MD26 FOR OPEN
1 Measure the resistance between the audio unit
C485 pin 12, circuit 9-MD26 (BN/YE) harness
side and the audio control switch C487 pin 2,
circuit 9-MD26 (BN/YE) harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new audio control switch. TEST
the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
NOTE: The video system will only operate when
the audio unit is switched on.

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DIAGNOSIS AND TESTING

PINPOINT TEST G: THE VIDEO SYSTEM IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

CONDITIONS DETAILS/RESULTS/ACTIONS
G1: CHECK VIDEO SYSTEM MODULE C552 CIRCUIT 29-MD16A (OG/GN) FOR VOLTAGE
1 Disconnect Video System Module C552.
2 Switch the audio unit ON.
3 Measure the voltage between the video system
module C552 pin 6, circuit 29-MD16A
(OG/GN), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to G2.
→ No
GO to G4.
G2: CHECK THE VIDEO SYSTEM MODULE C552 91-MD16A (BK) FOR GROUND
1 Measure the resistance between the video sys-
tem module C552 pin 12, circuit 91-MD16A
(BK), harness side and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to G3.
→ No
REPAIR the circuit. TEST the system for
normal operation.
G3: CHECK SWITCHED POWER TO VIDEO SYSTEM MODULE CIRCUIT 29S-MD16 (OG/GN)
WITH THE AUDIO UNIT SWITCHED ON
1 Switch the audio unit ON.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the video system
module C552 pin 1, circuit 29S-MD16
(OG/GN), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
G4: CHECK POWER CIRCUIT BETWEEN VIDEO SYSTEM MODULE C552 CIRCUIT 29-MD16A
(OG/GN) AND CENTRAL JUNCTION BOX (CJB) C501 CIRCUIT 29-MD15 (OG/BK) FOR OPEN
1 Disconnect Central Junction Box (CJB) C501.
2 Measure the resistance between the video sys-
tem module C552 pin 6, circuit 29-MD16A
(OG/GN), harness side and the CJB C501 pin
14, circuit 29-MD15 (OG/BK), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to G5.
→ No
REPAIR the circuit. TEST the system for
normal operation.
G5: CHECK SWITCHED POWER CIRCUIT BETWEEN VIDEO SYSTEM MODULE C552 CIRCUIT
29S-MD16 (OG/GN) AND AUDIO UNIT C489 (OG/GN) FOR OPEN
1 Disconnect Audio Unit C489.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the video sys-
tem module C552 pin 1, circuit 29S-MD16
(OG/GN), harness side and the audio unit
C489 pin 7, circuit 29S-MD16 (OG/GN), har-
ness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new audio unit. TEST the sys-
tem for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
PINPOINT TEST H: NO AUXILIARY HEADPHONE AUDIO
CONDITIONS DETAILS/RESULTS/ACTIONS
H1: CHECK THE HEADPHONE AND HEADPHONE SOCKETS
1 Using a known good headphone, check the
headphone in the right-hand and left-hand
sockets.
• Does the substitute headphone operate cor-
rectly?
→ Yes
INSTALL a new headphone. TEST the sys-
tem for normal operation.
→ No
No output from either channel, GO to H2.
No output from the right-hand channel,
GO to H4.
No output from the left-hand channel,
GO to H5.
H2: CHECK THE PASSENGER ENTERTAINMENT CONTROL PANEL C521 (RD) FOR VOLTAGE
1 Disconnect Passenger Entertainment Control
Panel C521.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the passenger
entertainment control panel C521 pin 6, (RD),
harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to H3.
→ No
GO to H6
H3: CHECK THE PASSENGER ENTERTAINMENT CONTROL PANEL C521 (BK) FOR GROUND
1 Measure the resistance between the passen-
ger entertainment control panel C521 pin 16,
(BK), harness side and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
REPAIR the circuit (BK). TEST the system
for normal operation.
H4: CHECK RIGHT-HAND HEADPHONE CIRCUIT (NO) FOR OPEN
1 Disconnect Video System Module C520.
2 Disconnect Passenger Entertainment Control
Panel C521.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistances between the video
system module C520 pin 1, (NO), harness side
and the passenger entertainment control panel
C521 pin 1, (NO), harness side; and between
the video system module C520 pin 4, (NO),
harness side and the passenger entertainment
control panel C521 pin 4, (NO), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to H7.
→ No
REPAIR the circuit(s) (NO). TEST the sys-
tem for normal operation
H5: CHECK LEFT-HAND HEADPHONE CIRCUIT (NO) FOR OPEN
1 Disconnect Video System Module C520.
2 Disconnect Passenger Entertainment Control
Panel C521.
3 Measure the resistances between the video
system module C520 pin 2, (NO), harness side
and the passenger entertainment control panel
C521 pin 2, (NO), harness side; and between
the video system module C520 pin 5, (NO),
harness side and the passenger entertainment
control panel C521 pin 5, (NO), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to I7.
→ No
REPAIR the circuit(s) (NO). TEST the sys-
tem for normal operation.
H6: CHECK POWER CIRCUIT BETWEEN VIDEO SYSTEM MODULE C520 (RD) AND
PASSENGER ENTERTAINMENT CONTROL PANEL C521 (RD) FOR OPEN
1 Disconnect Video System Module C520.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the video sys-
tem module C520 pin 6, (RD), harness side
and the passenger entertainment control panel
C521 pin 6, (RD), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to H7.
→ No
REPAIR the circuit (RD). TEST the system
for normal operation.
H7: CHECK THE PASSENGER ENTERTAINMENT CONTROL PANEL FOR CONTINUITY
1 Measure the resistance between the
passenger entertainment control panel C96,
component side and the headphone sockets:
- pins 4 and 5 and the left-hand headphone
sockets
- pins 1 and 2 and the right-hand headphone
sockets

• Are the resistances less than 0.5 ohms?

→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
INSTALL a new passenger entertainment
control panel. TEST the system for normal
operation.
PINPOINT TEST I: THE VIDEO DISPLAY IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Do not attempt to open or repair a video display as there are internal voltages in
excess of 2000 volts. Failure to follow this instruction may result in personal injury.
I1: CHECK OPERATION OF THE VIDEO DISPLAY
1 Change the head restraints/video displays be-
tween the two front seats.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Has the concern moved with the video display?

→ Yes
INSTALL a new head restraint/video dis-
play. TEST the system for normal operation.
→ No
For concern with right-hand video display,
GO to I2.
For concern with left-hand video display,
GO to I8.
I2: CHECK RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C529 CIRCUIT 15-
MD16A (OG) FOR VOLTAGE
1 Disconnect Right-Hand Front Seat Backrest
Upper Video System C557.
2 Measure the voltage between the right-hand
front seat backrest upper video system C557
pin 6, circuit 15-MD16A (OG), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to I3.
→ No
GO to I4.
I3: CHECK RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C557 CIRCUIT 48-
MD16A (NO) FOR GROUND
1 Measure the resistance between the right-hand
front seat backrest upper video system C557
pin 3, circuit 48-MD16A (NO), harness side
and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to I5.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR the circuit. TEST the system for
normal operation.
I4: CHECK POWER CIRCUIT BETWEEN RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO
C557 (OG) AND VIDEO SYSTEM MODULE C553 CIRCUIT 15-MD16A (OG) FOR OPEN
1 Disconnect Video System Module C553.
2 Measure the resistance between the right-hand
front seat backrest upper video system C557
pin 6, (OG), harness side and the video system
module C553 pin 6, circuit 15-MD16A (OG),
harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to I5.
→ No
REPAIR the circuit (OG). TEST the system
for normal operation
I5: CHECK RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C557 CIRCUIT 15-
XL21A (RD) FOR ILLUMINATION VOLTAGE
1 Measure the voltage between the right-hand
front seat backrest upper video system C557
pin 16, circuit 15-XL21A (RD), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to I6.
→ No
GO to I7.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
I6: CHECK RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C557 CIRCUIT 91-
XL21A (BK) FOR ILLUMINATION GROUND
1 Measure the resistance between the right-hand
front seat backrest upper video system C557
pin 13, circuit 91-XL21A (BK), harness side
and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to I7.
→ No
REPAIR the circuit. TEST the system for
normal operation.
I7: CHECK CIRCUIT BETWEEN RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM
C557 (RD) AND VIDEO SYSTEM MODULE C553 CIRCUIT 15-XL21A (RD) FOR OPEN
1 Disconnect Video System Module C553.
2 Measure the resistance between the right-hand
front seat backrest upper videosystem C557
pin 16, (RD), harness side and the video sys-
tem module C553 pin 10, circuit 15-XL21A
(RD), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
I8: CHECK LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C554 CIRCUIT 15-
MD16 (GN/OG) FOR VOLTAGE
1 Disconnect Front Seat Backrest Upper Video
System C554.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the left-hand
front seat backrest upper video system C554
pin 6, circuit 15-MD16 (GN/OG), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to I9.
→ No
GO to I10.
I9: CHECK LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C554 CIRCUIT 48-
MD16 (NO) FOR GROUND
1 Measure the resistance between the left-hand
front seat backrest upper video system C554
pin 3, circuit 48-MD16 (NO), harness side and
ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to I11.
→ No
REPAIR the circuit. TEST the system for
normal operation.
I10: CHECK POWER CIRCUIT BETWEEN LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO
C554 (GN/OG) AND VIDEO SYSTEM MODULE C553 CIRCUIT 15-MD16 (GN/OG) FOR OPEN
1 Disconnect Video System Module C553.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the left-hand
front seat backrest upper video system C554
pin 6, (GN/OG), harness side and the video
system module C553 pin 16, circuit 15-MD16
(GN/OG), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to I11.
→ No
REPAIR the circuit. TEST the system for
normal operation.
I11: CHECK LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C554 CIRCUIT 15-
XL1 (GN/BU) FOR ILLUMINATION VOLTAGE
1 Measure the voltage between the left-hand
front seat backrest upper video system C528
pin 16, circuit 15-XL1 (GN/BU), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to I12.
→ No
GO to I13.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
I12: CHECK LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM C528 CIRCUIT 91-
XL21 (BK) FOR ILLUMINATION GROUND
1 Measure the resistance between the left-hand
front seat backrest upper video system C554
pin 13, circuit 1-XL1 (WH/RD), harness side
and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to I13.
→ No
REPAIR the circuit. TEST the system for
normal operation.
I13: CHECK CIRCUIT BETWEEN LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM
C554 (RD) AND VIDEO SYSTEM MODULE C553 CIRCUIT 91-XL21 (RD) FOR OPEN
1 Disconnect Video System Module C553.
2 Measure the resistance between the left-hand
front seat backrest upper video system C554
pin 9, (WH/RD), harness side and the video
system module C553 pin 19, circuit 1-XL21
(WH/RD), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST J: THE VIDEO CASSETTE PLAYER IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
J1: CHECK VIDEO CASSETTE PLAYER C556 (RD) FOR VOLTAGE
1 Disconnect Video Cassette Player C556.
2 Switch the audio unit ON.
3 Measure the voltage between the video cas-
sette player C556 pin 4, (RD), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to J2.
→ No
GO to J3.
J2: CHECK VIDEO CASSETTE PLAYER C556 (BK) FOR GROUND
1 Measure the resistance between the video
cassette player C556 pin 2, (BK), harness side
and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to J5.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
J3: CHECK SWITCHED POWER CIRCUIT TO THE VIDEO CASSETTE PLAYER C556 (GN/BU)
1 Measure the voltage between the video cas-
sette player C556 pin 3, (GN/BU), harness side
and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new video cassette player.
TEST the system for normal operation.
→ No
GO to J4.
J4: CHECK POWER CIRCUIT BETWEEN VIDEO SYSTEM MODULE C552 CIRCUIT 15-XL2
(GN/BU) AND VIDEO CASSETTE PLAYER C556 (GN/BU) FOR OPEN
1 Disconnect Video System Module C552.
2 Measure the resistance between the video sys-
tem module C552 pin 4, circuit 15-XL2
(GN/BU), harness side and the video cassette
player C556 pin 4, (GN/BU), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to J5.
→ No
REPAIR the circuit. TEST the system for
normal operation.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
J5: CHECK SWITCHED POWER CIRCUIT BETWEEN THE VIDEO SYSTEM MODULE C552
CIRCUIT 15S-XL24 (OG) AND THE VIDEO CASSETTE PLAYER C519 (OG) FOR OPEN
1 Measure the resistance between the video sys-
tem module C552 pin 3, circuit 15S-XL2
(GN/BU), harness side and the video cassette
player C519 pin 3, (GN/BU), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
REPAIR the circuit. TEST the system for
normal operation.
PINPOINT TEST K: REMOTE CONTROL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
K1: CHECK OPERATION OF THE INFRARED SENSORS USING THE REMOTE CONTROL
NOTE: Refer to the Multimedia System Operating Guide for full operating instructions.
1 Operate the remote control while pointing it at
the infrared sensor of each video display in
turn.
2 Change the head restraints/video displays be-
tween the two front seats.
• Has the concern moved with the video display?
→ Yes
INSTALL a new head restraint/video dis-
play. TEST the system for normal operation.
→ No
For concern with right-hand video display,
GO to K2.
For concern with left-hand video display,
GO to K3.
K2: CHECK CIRCUIT BETWEEN RIGHT-HAND FRONT SEAT BACKREST UPPER VIDEO
SYSTEM C557 (WH) AND VIDEO SYSTEM MODULE C553 CIRCUIT 4-MD16A (WH) FOR OPEN
1 Disconnect Right-Hand Front Seat Backrest
Upper Video System C557.
2 Disconnect Video System Module C553.

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415-00-31 Entertainment System - General Information 415-00-31

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the right-hand
front seat backrest upper video system C557
pin 4, (WH), harness side and the video sys-
tem module C553 pin 4, circuit 4-MD16A (WH),
harness side.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to K4.
→ No
REPAIR the circuit. TEST the system for
normal operation.
K3: CHECK CIRCUIT BETWEEN LEFT-HAND FRONT SEAT BACKREST UPPER VIDEO SYSTEM
C554 (WH) AND VIDEO SYSTEM MODULE C553 CIRCUIT 4-MD16 (WH) FOR OPEN
1 Disconnect Front Seat Backrest Upper Video
System C554.
2 Disconnect Video System Module C553.
3 Measure the resistance between the left-hand
front seat backrest upper video system C554
pin 4, (WH), harness side and the video sys-
tem module C553 pin 14, circuit 4-MD16 (WH),
harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to K4.
→ No
REPAIR the circuit. TEST the system for
normal operation.
K4: CHECK THE VIDEO CASSETTE PLAYER OPERATION USING THE CONTROLS ON THE
VIDEO CASSETTE PLAYER
1 Operate the video cassette player using the
controls on the video cassette player.
• Does the video cassette player operate cor-
rectly?

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415-00-32 Entertainment System - General Information 415-00-32

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
INSTALL a new remote control. TEST the
system for normal operation.
→ No
INSTALL a new video system module.
TEST the system for normal operation.
PINPOINT TEST L: EXTERNAL GAME CONSOLE/MEDIA SOURCE IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: An inverter is required (not supplied by Ford) to convert the vehicle battery
voltage to mains voltage to power external games consoles etc. Make sure the inverter ca-
ble has not become broken, split or damaged. Failure to follow this instruction may result
in personal injury.
NOTE: Make sure that the external game console/media source device operates correctly out of the
vehicle before commencing diagnostics.
L1: CHECK PASSENGER ENTERTAINMENT CONTROL PANEL C521 (VT) FOR AUDIO GROUND
1 Disconnect Passenger Entertainment Control
Panel C521.
2 Measure the resistance between the passen-
ger entertainment control panel C521 pin 15,
(VT), harness side and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to L2.
→ No
REPAIR the circuit (VT). TEST the system
for normal operation.

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415-00-33 Entertainment System - General Information 415-00-33

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
L2: CHECK PASSENGER ENTERTAINMENT CONTROL PANEL C521 (BN) FOR VIDEO GROUND
1 Measure the resistance between the passen-
ger entertainment control panel C521 pin 12,
(BN), harness side and ground.

• Is the resistance less than 0.5 ohms?

→ Yes
GO to L3.
→ No
REPAIR the circuit (BN). TEST the system
for normal operation.
L3: CHECK VIDEO CIRCUIT BETWEEN PASSENGER ENTERTAINMENT CONTROL PANEL C521
(YE) AND VIDEO SYSTEM MODULE C520 (YE)
1 Disconnect Video System Module C520.
2 Measure the resistance between the passen-
ger entertainment control panel C521 pin 1,1
(YE), harness side and the video system mod-
ule C520 pin 7, (YE), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to L4.
→ No
REPAIR the circuit (YE). TEST the system
for normal operation.

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415-00-34 Entertainment System - General Information 415-00-34

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
L4: CHECK RIGHT-HAND AUDIO CIRCUIT BETWEEN PASSENGER ENTERTAINMENT
CONTROL PANEL C521 (BU) AND VIDEO SYSTEM MODULE C520 (BU)
1 Measure the resistance between the passen-
ger entertainment control panel C521 pin 13,
(BU), harness side and the video system mod-
ule C520 pin 9, (BU), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to L5.
→ No
REPAIR the circuit (BU). TEST the system
for normal operation.
L5: CHECK LEFT-HAND AUDIO CIRCUIT BETWEEN PASSENGER ENTERTAINMENT CONTROL
PANEL C521 (GN) AND VIDEO SYSTEM MODULE C520 (GN)
1 Measure the resistance between the passen-
ger entertainment control panel C521 pin 14,
(GN), harness side and the video system mod-
ule C520 pin 10, (GN), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to L6.
→ No
REPAIR the circuit (GN). TEST the system
for normal operation.

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415-00-35 Entertainment System - General Information 415-00-35

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
L6: CHECK THE PASSENGER ENTERTAINMENT CONTROL PANEL FOR CONTINUITY
1 Measure the resistances between the
passenger entertainment control panel C521,
component side and the auxiliary input
sockets:
- pin 11 and the yellow video input socket
center pin
- pin 12 and the yellow video input socket outer
shield
- pin 13 and the red audio input socket center
pin
- pin 14 and the white audio input socket center
pin
- pin 15 and the red audio input socket outer
shield
- pin 15 and the white audio input socket outer
shield
• Are the resistances less than 0.5 ohms?
→ Yes
INSTALL a new video system module.
TEST the system for normal operation.
→ No
INSTALL a new passenger entertainment
control panel. TEST the system for normal
operation.
PINPOINT TEST M: CD CHANGER IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
M1: CHECK IN-LINE FUSE
1 CHECK Fuse F101 (3A).
2 Check in-line fuse F101 (3A) for the CD
changer.
• Is the fuse OK?
→ Yes
GO to M2.
→ No
INSTALL a new fuse. TEST the system for
normal operation.
M2: TEST THE AUDIO UNIT TO CD CHANGER WIRING HARNESS
1 Disconnect CD Changer C465.
2 Disconnect Audio Unit C464 (Standard Audio
Unit or Travel Pilot Navigation) or C1464 (9000
Vehicle Navigation Radio (VNR)).
3 Carry out the CD changer wiring harness com-
ponent test, REFER to the Component Test in
this Section.
• Is the audio unit to CD changer wiring harness
OK?
→ Yes
GO to M3.

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415-00-36 Entertainment System - General Information 415-00-36

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR the CD changer wiring harness.
TEST the system for normal operation.
M3: CHECK FOR CORRECT OPERATION OF CD CHANGER
1 Substitute a known good CD changer.
2 Verify correct operation of the substitute CD
changer.
• Do all CD changer functions operate correctly?
→ Yes
INSTALL a new CD changer. REFER to
Section 415-01. TEST the system for nor-
mal operation.
→ No
REMOVE the substitute CD changer and
INSTALL the original CD changer. INSTALL
a new audio unit. TEST the system for nor-
mal operation.
NOTE: Refer to the Wiring Diagram, Section 415-
00 or Section 419-07 for Schematic and
Component Tests Connector information.
CD Changer Wiring Harness 1. Test the CD changer wiring harness using
the following table as a guide to meter lead
placement as well as expected values.

Vehicles With Standard Audio Unit or Travel Pilot Navigation

CD Changer C465 Audio Unit C464 Expected Value
Pin 1 Pin 10 Less than 5 ohms
Pin 3 Pin 15 Less than 5 ohms
Pin 5 Pin 19 Less than 5 ohms
Pin 6 Pin 20 Less than 5 ohms
Pin 7 Pin 11 Less than 5 ohms
Pin 8 Pin 13 Less than 5 ohms
Pin 9 Pin 14 Less than 5 ohms
Pin 10 Pin 18 Less than 5 ohms
Pin 11 Pin 16 Less than 5 ohms
Pin 12 Pin 17 Less than 5 ohms

CD Changer C465 Ground Expected Value

Pin 1 Ground Greater than 10,000 ohms
Pin 3 Ground Greater than 10,000 ohms
Pin 5 Ground Greater than 10,000 ohms
Pin 6 Ground Greater than 10,000 ohms
Pin 7 Ground Greater than 10,000 ohms
Pin 8 Ground Greater than 10,000 ohms
Pin 9 Ground Greater than 10,000 ohms
Pin 10 Ground Greater than 10,000 ohms
Pin 11 Ground Greater than 10,000 ohms
Pin 12 Ground Greater than 10,000 ohms

Vehicles With 9000 Vehicle Navigation Radio (VNR)

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415-00-37 Entertainment System - General Information 415-00-37

DIAGNOSIS AND TESTING

CD Changer C465 Audio Unit C1464 Expected Value

Pin 1 Pin 1 Less than 5 ohms
Pin 3 Pin 3 Less than 5 ohms
Pin 5 Pin 5 Less than 5 ohms
Pin 6 Pin 6 Less than 5 ohms
Pin 7 Pin 7 Less than 5 ohms
Pin 8 Pin 8 Less than 5 ohms
Pin 9 Pin 9 Less than 5 ohms
Pin 10 Pin 10 Less than 5 ohms
Pin 11 Pin 11 Less than 5 ohms
Pin 12 Pin 12 Less than 5 ohms

CD Changer C465 Ground Expected Value

Pin 1 Ground Greater than 10,000 ohms
Pin 3 Ground Greater than 10,000 ohms
Pin 5 Ground Greater than 10,000 ohms
Pin 6 Ground Greater than 10,000 ohms
Pin 7 Ground Greater than 10,000 ohms
Pin 8 Ground Greater than 10,000 ohms
Pin 9 Ground Greater than 10,000 ohms
Pin 10 Ground Greater than 10,000 ohms
Pin 11 Ground Greater than 10,000 ohms
Pin 12 Ground Greater than 10,000 ohms
2. If routed here from a Pinpoint Test, return to
the Pinpoint Test.

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415-01-1 Audio Unit 415-01-1

SECTION 415-01 Audio Unit

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Audio System .................................................................................................................... 415-01-2

REMOVAL AND INSTALLATION

Compact Disc (CD) Changer ............................................................................................. 415-01-3

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415-01-2 Audio Unit 415-01-2

DIAGNOSIS AND TESTING

Audio System
DIAGNOSIS AND TESTING

REFER to Section 415-00.

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415-01-3 Audio Unit 415-01-3

REMOVAL AND INSTALLATION

Compact Disc (CD) Changer

REMOVAL AND INSTALLATION

Removal
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the passenger seat assembly. For
additional information, refer to Section
501-10.
3. NOTE: Lay the seat onto its back to allow
access to the CD autochanger.
Remove the retaining screws from either
side and detach the CD autochanger from
its mounting bracket.

4. Disconnect the electrical connector and

remove the CD autochanger.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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415-02-1 Antenna 415-02-1

SECTION 415-02 Antenna

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Antenna............................................................................................................................. 415-02-2

DIAGNOSIS AND TESTING

Antenna............................................................................................................................. 415-02-4

REMOVAL AND INSTALLATION

Antenna Cable................................................................................................................... 415-02-5

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415-02-2 Antenna 415-02-2

DESCRIPTION AND OPERATION

Antenna
DESCRIPTION AND OPERATION

Antenna

Item Part Description

Item Part Description Number
Number
3 Insulator clip
1 Antenna mast
4 Antenna cable
2 Antenna base
5 Retaining screw

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415-02-3 Antenna 415-02-3

DESCRIPTION AND OPERATION

Antenna Cable Routing

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415-02-4 Antenna 415-02-4

DIAGNOSIS AND TESTING

Antenna
DIAGNOSIS AND TESTING

REFER to Section 415-00.

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415-02-5 Antenna 415-02-5

REMOVAL AND INSTALLATION

Antenna Cable
REMOVAL AND INSTALLATION

6. Detach the right-hand front door weather

strip.
General Equipment
Suitable draw cord with a minimum length of
three meters

Removal
1. Remove the audio unit. For additional
information, refer to Section 415-01.
2. Remove the overhead console. For
additional information, refer to Section
501-12.
3. Disconnect the antenna cable from the an-
tenna base. 7. Detach the right-hand cowl trim panel.

4. Remove the right-hand A-pillar trim panel. 8. Detach the right-hand rear door weather
For additional information, refer to Section strip.
501-05.
5. Remove the right-hand trim panel from the
floor console.

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415-02-6 Antenna 415-02-6

REMOVAL AND INSTALLATION (Continued)

9. Detach the right-hand cowl trim panel. 12. Remove the right-hand cowl trim panel
(to aid removal lift the rear seat cushion).

10. Detach the right-hand lower B-pillar trim

panel. 13. Detach the floor covering.

11. Detach the right-hand cowl trim panel. 14. Detach the antenna cable from the floor.

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415-02-7 Antenna 415-02-7

REMOVAL AND INSTALLATION (Continued)

15. Attach a suitable draw cord to the an-

tenna cable.

16. Pull the antenna cable down the A-pillar

to expose the suitable draw cord.
17. Detach the suitable draw cord and
remove the antenna cable.

Installation
1. To install, reverse the removal procedure.

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415-03-1 Speakers 415-03-1

SECTION 415-03 Speakers

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Speakers ........................................................................................................................... 415-03-2

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415-03-2 Speakers 415-03-2

DIAGNOSIS AND TESTING

Speakers
DIAGNOSIS AND TESTING

REFER to Section 415-00.

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417-01-1 Exterior Lighting 417-01-1

SECTION 417-01 Exterior Lighting

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 417-01-3

DESCRIPTION AND OPERATION

Exterior Lighting ................................................................................................................ 417-01-4

Xenon Headlamps............................................................................................................ 417-01-4
Function ........................................................................................................................... 417-01-4
Conventional Headlamps ................................................................................................. 417-01-4
Headlamp Levelling System – Xenon Headlamps ............................................................ 417-01-5
Headlamp Levelling System – Conventional Headlamps.................................................. 417-01-5
Headlamp Cleaning System ............................................................................................. 417-01-5

DIAGNOSIS AND TESTING

Headlamps ........................................................................................................................ 417-01-7

Diagnosis and Testing ...................................................................................................... 417-01-7
Symptom Chart ................................................................................................................ 417-01-7
Pinpoint Tests .................................................................................................................. 417-01-8
Stoplamps ......................................................................................................................... 417-01-40
Inspection and Verification ............................................................................................... 417-01-40
Pinpoint Tests .................................................................................................................. 417-01-40
Turn Signal and Hazard Lamps ......................................................................................... 417-01-52
Inspection and Verification ............................................................................................... 417-01-52
Symptom Chart ................................................................................................................ 417-01-52
Pinpoint Tests .................................................................................................................. 417-01-53
Parking, Rear and License Lamps..................................................................................... 417-01-85
Inspection and Verification ............................................................................................... 417-01-85
Symptom Chart ................................................................................................................ 417-01-85
Pinpoint Tests .................................................................................................................. 417-01-86
Fog Lamps ........................................................................................................................ 417-01-102
Diagnosis and Testing ...................................................................................................... 417-01-102
Symptom Chart ................................................................................................................ 417-01-102
Pinpoint Tests .................................................................................................................. 417-01-102
Reversing Lamps............................................................................................................... 417-01-115
Diagnosis and Testing ...................................................................................................... 417-01-115
Symptom Chart ................................................................................................................ 417-01-115
Pinpoint Tests .................................................................................................................. 417-01-115
Trailer Lamps .................................................................................................................... 417-01-125
Diagnosis and Testing ...................................................................................................... 417-01-125
Symptom Chart ................................................................................................................ 417-01-125
Pinpoint Tests .................................................................................................................. 417-01-126
Headlamp Leveling............................................................................................................ 417-01-162
Diagnosis and testing ....................................................................................................... 417-01-162
Symptom Chart ................................................................................................................ 417-01-162
Pinpoint Tests .................................................................................................................. 417-01-162

GENERAL PROCEDURES

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417-01-2 Exterior Lighting 417-01-2

Headlamp Adjustment — Vehicles With: High Intensity Discharge Head- (32 113 0)
lamps ........................................................................................................... 417-01-185
Headlamp Adjustment................................................................................... (32 113 0) 417-01-186
Front Fog Lamp Adjustment............................................................................................... 417-01-187
Headlamp Masking — Vehicles With: High Intensity Discharge Headlamps....................... 417-01-188

REMOVAL AND INSTALLATION

Headlamp Bulb — Vehicles With: High Intensity Discharge Headlamps........ (32 147 0) 417-01-189
Headlamp Assembly ..................................................................................... (32 115 0) 417-01-190
Headlamp Leveling Sensor — Vehicles With: High Intensity Discharge Headlamps .......... 417-01-191

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417-01-3 Exterior Lighting 417-01-3

SPECIFICATIONS

Exterior Lighting
Component Type
Conventional headlamps Complex reflector system, alignment achieved by adjusting the reflector
Xenon headlamps Complex reflector system, alignment achieved by adjusting the reflector
Fog lamps Reflector system, alignment achieved by adjusting the reflector

Headlamp Adjustment
Component X value
Headlamps X = 10 cm/10 m = 0 degrees 34 minutes = 1.0%
Front fog lamps X = 22 cm/10 m = 1 degree 16 minutes = 2.2%

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417-01-4 Exterior Lighting 417-01-4

DESCRIPTION AND OPERATION

Exterior Lighting
DESCRIPTION AND OPERATION

zones could cause disturbing changes in the road

surface illumination when the vehicle is moving.
Xenon Headlamps In all, the Xenon headlamps produce a significant
improvement in active safety.
With Xenon headlamps the full brightness is only
achieved after about one minute of switching on.
Therefore, usage in motor vehicles require
special electronics to ensure full brightness in the
first second.
The arc chamber of the Xenon bulb is filled with
Xenon gas and a mixture of metal halide salts.
A high voltage of 20 kV surge ignites the arc
between the two electrodes. After a brief excess
current phase in which the arc stabilizes, the
lamp output is regulated to 35 watts by the
electronics.
Xenon headlamps are optional, which produce The bulb wear is so low that the Xenon bulb lasts
the low beam by a 35 Watt Xenon bulb. The the life of the vehicle.
Xenon bulb produces three times the light of the
conventional H7 bulb. The front side lamps and turn signal lamps are
integrated into the headlamp housing.
The headlamp assembly consists of the following
components:
– Headlamp housing Conventional Headlamps
– Headlamp housing cover
– Xenon bulb for low beam
– Halogen bulb for high beam and headlamp
flash
– Turn signal bulb
– Parking lamp bulb
– Headlamp levelling motor
– Starter module
– Control module

Function
WARNING: Voltages of up to 30 kV are NOTE: When changing bulbs, make sure that
possible. bulbs with a special coating are used in place of
conventional H1 or H7 bulbs so as to avoid
Like sunlight, the light produced has very high yellowing of the plastic lenses from the inside.
levels of green and blue fraction.
The front side lamps and turn signal lamps are
The special design of the bezel and the diffuser integrated into the headlamp housing. The
produce a significantly increased range and a headlamp assembly is fitted with a H7 bulb for
much broader short range spread. This allows the low beam and a H1 bulb for the high beam
better illumination of the side of the road without and the headlamp flash.
exceeding the statutory limits for causing dazzle.
Another advantage of the chosen light distribution
is softening of the light and dark boundary.
Excessive contrast between the light and dark
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417-01-5 Exterior Lighting 417-01-5

DESCRIPTION AND OPERATION (Continued)

Headlamp Levelling System – Xenon pivoting reflector by means of an adjustment

Headlamps spindle until it reaches the required setting.
An automatic headlamp levelling system is The headlamp levelling control switch has two
required for vehicles with Xenon headlamps to stops. The switch clicks in position ""0”, which
comply with national legislation. corresponds to the basic setting. The headlamps
are inclined upwards at their maximum angle
The system consists of the following
when the switch is set to position ""4”.
components:
The headlamp levelling system is operated by
– Vehicle level sensors on the front and rear
means of voltage controlled direct current (DC)
axles
motors. A potentiometer inside the headlamp
– Master control module on the left-hand levelling switch is used to adjust a voltage
headlamp housing (required value). Following the same principle,
– Slave control module on the right-hand the actuator in the motor produces a voltage that
headlamp housing depends on the position of the adjustment
– Headlamp levelling motors in both headlamp spindle (actual value).
housings The electronics built into these systems
The system automatically adjusts to the laden compares the required value (setting of the
state of the vehicle when the ignition is switched switch) with the actual value (adjustment spindle
on to avoid dazzling of oncoming traffic. setting). Depending on the voltage difference the
reflectors are swivelled up or down until the two
No adjustment of the range take place during voltages are the same.
dynamic processes (braking, accelerating, initial
drive). In case of a signal failure the system adjusts to a
safety position (low beam) to comply with
NOTE: After removing a headlamp level sensor national legislation.
or disconnecting of the electrical circuit, a new
calibration of the headlamp levelling system is
required and must be initialized with WDS. Headlamp Cleaning System
A vehicle level sensor on the front and rear axle A headlamp cleaning system is required for
sends the master control module a voltage signal vehicles with Xenon headlamps to comply with
according to the suspension compression. This national legislation. This takes the form of a high-
master control module calculates the inclination pressure washer system.
of the headlamps according to the difference
between the two signals and sends the required When inactive, the telescopic nozzle holder is
position to the slave control module. Both concealed in the bumper.
modules generate the control signal for the As soon as the windshield washer system is
headlamp levelling motors in comparison of the operated with the headlamps switched on, the
present reflector position to the required reflector telescopic nozzle holder extends and cleans the
position. external surface of the headlamp (plastic cover)
When the low beam is switched on, the system with a high-pressure jet of water.
compares actual conditions with original An additional high-pressure pump is mounted on
adjustment. This prevents a reduction in road the washer fluid reservoir for the high-pressure
surface illumination and avoids dazzling of washer system.
oncoming traffic.

Headlamp Levelling System – Conventional

Headlamps
NOTE: Basic adjustment of the headlamps must
always be carried out with the headlamp levelling
switch set to position ""0”.
Each headlamp unit incorporates a levelling
motor, which is activated electrically and
controlled by the switch. The motor moves the
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417-01-6 Exterior Lighting 417-01-6

DESCRIPTION AND OPERATION (Continued)

Item Description
1 Cover
2 Nozzle holder

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417-01-7 Exterior Lighting 417-01-7

DIAGNOSIS AND TESTING

Headlamps
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Diagnosis and Testing
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electrical damage.
device
Visual inspection
Electrical
• Fuse(s).
Terminal probe kit • Bulb(s).
29-011 A • Electrical connector(s).
• Switch(es).
• Wiring harness.
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Dipped beam and main beam • Fuse(s). • GO to Pinpoint Test A
are completely inoperative • Circuit(s).
• Ignition switch
• Light switch
• Central junction box (CJB).
• Dipped beam is completely in- • Fuse(s). • GO to Pinpoint Test B
operative • Circuit(s).
• Dipped beam relay
(conventional headlamps)
• Gas discharge headlamp relay.
• Central junction box (CJB).
• One dipped beam inoperative • Fuse(s). • GO to Pinpoint Test C
• Circuit(s).
• Headlamps
• Main beam is completely inop- • Circuit(s). • GO to Pinpoint Test D
erative • Main beam relay.
• Turn signal switch
• Central junction box (CJB).
• One main beam inoperative • Fuse(s). • GO to Pinpoint Test E
• Circuit(s).
• Headlamp assembly.
• Central junction box (CJB).

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417-01-8 Exterior Lighting 417-01-8

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• The headlamp are on continu- • Circuit(s). • GO to Pinpoint Test F
ously • Light switch
• Turn signal switch
• Main beam relay.
• Dipped beam relay
(conventional headlamps)
• Gas discharge headlamp relay.
• Central junction box (CJB).

Pinpoint Tests
PINPOINT TEST A: DIPPED BEAM AND MAIN BEAM ARE COMPLETELY INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FUSE F88 (CJB)
1 Key in OFF position.
2 CHECK Fuse F88 (CJB).
3 Check fuse F88 (15 A).
• Is the fuse OK?
→ Yes
GO to A2
→ No
INSTALL a new fuse F88 (15 A). CHECK
the operation of the system. If the fuse
blows again, LOCATE and REPAIR the
short to groundof the circuit(s) by using the
wiring diagrams.
A2: CHECK THE VOLTAGE AT FUSE F88 (CJB)
1 Connect Fuse F88 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F88 (CJB)
and ground.
• Is battery voltage indicated?
→ Yes
GO to A4
→ No
GO to A3
A3: CHECK CIRCUIT 15-DA2 (GN/BU) BETWEEN THE IGNITION SWITCH AND FUSE F88 (CJB)
1 Key in OFF position.
2 Disconnect Ignition switch C400.

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417-01-9 Exterior Lighting 417-01-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Use a fused test cable (15 A) to bridge the igni-
tion switch, connector C400, pin 1, circuit 15-
DA2 (GN/BU) and pin 4, circuit 30-BB9 (RD),
wiring harness side.

4 Switch on the dipped beam.

5 Check the dipped beams.
• Does the dipped beam illuminate?
→ Yes
RENEW the ignition switch. CHECK the
operation of the system.
→ No
REPAIR the open circuit between the igni-
tion switch and fuse F88 (CJB) with the aid
of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
A4: CHECK THE VOLTAGE AT THE LIGHT SWITCH
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Key in ON position.
4 Measure the voltage between the light switch,
connector C478, pin 8, circuit 15-LE21
(GN/BK), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
Renew the light switch. CHECK the opera-
tion of the system.
→ No

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417-01-10 Exterior Lighting 417-01-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit between fuse F88
(CJB) and the light switch with the aid of
the Wiring Diagrams, if necessary RENEW
the central junction box (CJB). CHECK the
operation of the system.
PINPOINT TEST B: DIPPED BEAM IS COMPLETELY INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: DETERMINE THE MODEL
1 Determine the model variant.
• Is the vehicle equipped with gas discharge
headlamps?
→ Yes
GO to B7
→ No
GO to B2
B2: CHECK FUSE F95 (CJB)
1 Key in OFF position.
2 CHECK Fuse F95 (CJB).
3 Check fuse F95 (7,5 A).
• Is the fuse OK?
→ Yes
GO to B3
→ No
INSTALL a new fuse F95 (7,5 A). If the
fuse blows again, LOCATE and RECTIFY
the short to ground using the wiring dia-
grams. CHECK the operation of the sys-
tem.
B3: CHECK THE VOLTAGE AT THE WORKING CIRCUIT OF THE DIPPED BEAM RELAY
1 Disconnect Dipped beam relay C901.
2 Key in ON position.
3 Measure the voltage between dipped beam
relay, connector C901, pin 5, circuit15-LE19
(GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to B4
→ No

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the break in circuit 15-LE19
(GN/BU) with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
B4: CHECK THE VOLTAGE AT THE CONTROL CIRCUIT OF THE DIPPED BEAM RELAY
1 Key in OFF position.
2 Connect Fuse F95 (CJB).
3 Key in ON position.
4 Switch on the dipped beam.
5 Measure the voltage between dipped beam
relay, connector C901, pin 2, circuit15S-LE19
(GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to B6
→ No
GO to B5
B5: CHECK THE CIRCUIT 15S-LE19
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Measure the resistance between the dipped
beam relay, connector C901, pin 2, circuit 15S-
LE19 (GN/BU), BJB side and the light switch
C478, pin 6, circuit 15S-LE19 (GN/BU), wiring
harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to B6
→ No

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit between the light
switch and the dipped beam relay with the
aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
B6: CHECK THE GROUND CONNECTION OF THE DIPPED BEAM RELAY
1 Key in OFF position.
2 Measure the resistance between dipped beam
relay, connector C901, pin 1,circuit 31-LE19
(BK), BJB side and ground.

• Is the resistance less than 2 ohms?

→ Yes
INSTALL a new dipped beam relay. CHECK
the operation of the system.
→ No
REPAIR the break in circuit 31-LE19 (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
B7: CHECK FUSE F95 (CJB)
1 Key in OFF position.
2 CHECK Fuse F95 (CJB).
3 Check fuse F95 (7,5 A).
• Is the fuse OK?
→ Yes
GO to B8
→ No
INSTALL a new fuse F95 (7,5 A). If the
fuse blows again, LOCATE and RECTIFY
the short to ground using the wiring dia-
grams. CHECK the operation of the sys-
tem.
B8: READ OUT THE FAULT MEMORY
1 Connect the diagnostic tool.
2 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
GO to B9
B9: CHECK THE VOLTAGE AT THE WORKING CIRCUIT OF THE GAS DISCHARGE HEADLAMP
RELAY
1 Disconnect Gas discharge headlamp relay
C901.
2 Measure the voltage between gas discharge
headlamp relay, connector C901, pin5, circuit
30-LE19 (RD), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to B10
→ No
REPAIR the break in circuit 30-LE19 (RD)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
B10: CHECK THE VOLTAGE AT THE CONTROL CIRCUIT OF THE GAS DISCHARGE
HEADLAMP RELAY
1 Connect Fuse F95 (CJB).
2 Key in ON position.
3 Switch on the dipped beam.
4 Measure the voltage between gas discharge
headlamp relay, connector C901, pin2, circuit
15S-LE19 (GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to B12
→ No
GO to B11

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417-01-14 Exterior Lighting 417-01-14

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B11: CHECK CIRCUIT 15S-LE19 (GN/BU) BETWEEN THE LIGHT SWITCH AND THE GAS
DISCHARGE HEADLAMP RELAY
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Measure the resistance between the gas dis-
charge headlamp relay, connector C901, pin 2,
circuit 15S-LE19 (GN/BU), BJB side and the
light switch C478, pin 6, circuit 15S-LE19
(GN/BU), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to B12
→ No
REPAIR the break in circuit 15S-LE19
(GN/BU) between the light switch and the
gas discharge headlamp relay with the aid
of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
B12: CHECK THE GROUND CONNECTION OF THE GAS DISCHARGE HEADLAMP RELAY
1 Key in OFF position.
2 Measure the resistance between gas dis-
charge headlamp relay, connector C901, pin 1,
circuit 31-LE19 (BK), BJB side and ground.

• Is the resistance less than 2 ohms?

→ Yes
INSTALL a new gas discharge headlamp re-
lay. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE19 (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.

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417-01-15 Exterior Lighting 417-01-15

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: ONE DIPPED BEAM INOPERATIVE

CONDITIONS DETAILS/RESULTS/ACTIONS
C1: DETERMINE THE MODEL
1 Determine the model variant.
• Is the vehicle equipped with gas discharge
headlamps?
→ Yes
GO to C11
→ No
GO to C2
C2: DETERMINE THE INOPERATIVE LAMP
1 Key in ON position.
2 Switch on the dipped beam.
3 Check the dipped beams.
• Is the left-hand dipped beam inoperative?
→ Yes
GO to C3
→ No
The right-hand dipped beam is inoperative:
GO to C7
C3: CHECK FUSE F16 (BJB)
1 Key in OFF position.
2 CHECK Fuse F16 (BJB).
3 Check fuse F16 (7,5 A).
• Is the fuse OK?
→ Yes
GO to C4
→ No
INSTALL a new fuse F16 (7,5 A). CHECK
the operation of the system. If the fuse
blows again, LOCATE and REPAIR the
short to groundof the circuit(s) by using the
wiring diagrams.
C4: CHECK THE CIRCUIT BETWEEN THE DIPPED BEAM RELAY AND FUSE F16 (BJB)
1 Disconnect Dipped beam relay C901.
2 Measure the resistance between the dipped
beam relay, connector C901, pin 3, circuit 15S-
LE16A (GN/OG), BJB side and fuse F16 (BJB).

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417-01-16 Exterior Lighting 417-01-16

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 2 ohms?

→ Yes
GO to C5
→ No
REPAIR the break in circuit 15S-LE16A
(GN/OG) between the dipped beam relay
and fuse F16 (BJB) with the aid of the Wir-
ing Diagrams. CHECK the operation of the
system.
C5: CHECK THE CIRCUIT TO FUSE F16 (BJB)
1 Connect Fuse F16 (BJB).
2 Connect Dipped beam relay C901.
3 Disconnect Left-hand headlamp C146.
4 Key in ON position.
5 Switch on the dipped beam.
6 Measure the voltage between left-hand head-
lamp, connector C146, pin 1, circuit 15S-LE16
(GN/OG), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to C6
→ No
REPAIR the break in circuit 15S-LE16
(GN/OG) between fuse F16 (BJB) and the
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.

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417-01-17 Exterior Lighting 417-01-17

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C6: CHECK THE GROUND CONNECTION OF THE LEFT-HAND HEADLAMP
1 Measure the resistance between left-hand
headlamp, connector C146, pin 7, circuit 31-
LE31 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE31 (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
C7: CHECK FUSE F18 (BJB)
1 Key in OFF position.
2 CHECK Fuse F18 (BJB).
3 Check fuse F18 (7,5 A).
• Is the fuse OK?
→ Yes
GO to C8
→ No
INSTALL a new fuse F18 (7,5 A). If the
fuse blows again, LOCATE and RECTIFY
the short to ground using the wiring dia-
grams. CHECK the operation of the sys-
tem.
C8: CHECK THE CIRCUIT BETWEEN THE GAS DISCHARGE HEADLAMP RELAY AND FUSE F18
(BJB)
1 Connect Fuse F18 (BJB).

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417-01-18 Exterior Lighting 417-01-18

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the dipped
beam relay, connector C901, pin 3, BJB side
and fuse F18 (BJB).

• Is the resistance less than 2 ohms?

→ Yes
GO to C9
→ No
REPAIR the break in circuit 15S-LE23A
(GN/WH) between the dipped beam relay
and fuse F18 (BJB) with the aid of the Wir-
ing Diagrams. CHECK the operation of the
system.
C9: CHECK THE CIRCUIT TO FUSE F18 (BJB)
1 Disconnect Right-hand headlamp C147.
2 Key in ON position.
3 Switch on the dipped beam.
4 Measure the voltage between the right-hand
headlamp, connector C147, pin 1, circuit 15S-
LE23 (GN/WH), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to C10
→ No
REPAIR the break in circuit 15S-LE23
(GN/WH) between fuse F18 (BJB) and the
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
C10: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND HEADLAMP
1 Key in OFF position.
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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between right-hand
headlamp, connector C147, pin 7, circuit 31-
LE30 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE30 (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
C11: DETERMINE THE INOPERATIVE LAMP
1 Key in ON position.
2 Switch on the dipped beam.
3 Check the dipped beams.
• Is the left-hand dipped beam inoperative?
→ Yes
GO to C12
→ No
The right-hand dipped beam is inoperative:
GO to C17
C12: CHECK FUSE F16
1 Key in OFF position.
2 CHECK Fuse F16 (BJB).
3 Check fuse F16 (20 A).
• Is the fuse OK?
→ Yes
GO to C13
→ No
INSTALL a new fuse F16 (20 A). If the fuse
blows again, LOCATEand REPAIR the
short to ground of the circuit(s) by using the
wiring diagrams.CHECK the operation of
the system.
C13: READ OUT THE FAULT MEMORY
1 Connect the diagnostic tool.
2 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?

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417-01-20 Exterior Lighting 417-01-20

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.
→ No
GO to C14
C14: CHECK THE CIRCUIT BETWEEN THE GAS DISCHARGE HEADLAMP RELAY AND FUSE
F16 (BJB)
1 Key in OFF position.
2 Disconnect Gas discharge headlamp relay
C901.
3 Connect Fuse F16 (BJB).
4 Measure the resistance between the gas dis-
charge headlamp relay, connector C901, pin 3,
circuit 15S-LE16A (GN/OG), BJB side and fuse
F16 (BJB).

• Is the resistance less than 2 ohms?

→ Yes
GO to C15
→ No
REPAIR the break in circuit 15S-LE16A
(GN/OG) between the gas discharge head-
lamp relay and fuse F16 (BJB) with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
C15: CHECK THE CIRCUIT TO FUSE F16 (BJB)
1 Connect Gas discharge headlamp relay C901.
2 Disconnect Left-hand headlamp C146.
3 Key in ON position.
4 Switch on the dipped beam.

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417-01-21 Exterior Lighting 417-01-21

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between left-hand head-
lamp, connector C1146, pin 14, circuit 15S-
LE16 (GN/OG), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to C16
→ No
REPAIR the break in circuit 15S-LE16
(GN/OG) between fuse F16 (BJB) and the
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
C16: CHECK THE GROUND CONNECTION OF THE HEADLAMP
1 Key in OFF position.
2 Measure the resistance between left-hand
headlamp, connector C1146 11, circuit 31-
LE31 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE31 (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
C17: CHECK FUSE F18 (BJB)
1 Key in OFF position.
2 CHECK Fuse F18 (BJB).
3 Check fuse F18 (20 A).

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417-01-22 Exterior Lighting 417-01-22

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the fuse OK?

→ Yes
GO to C18
→ No
INSTALL a new fuse F18 (20 A). If the fuse
blows again, LOCATEand REPAIR the
short to ground of the circuit(s) by using the
wiring diagrams.CHECK the operation of
the system.
C18: READ OUT THE FAULT MEMORY
1 Connect the diagnostic tool.
2 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.
→ No
GO to C19
C19: CHECK THE CIRCUIT BETWEEN THE GAS DISCHARGE HEADLAMP RELAY AND FUSE
F18 (BJB)
1 Key in OFF position.
2 Connect Fuse F18 (BJB).
3 Disconnect Gas discharge headlamp relay
C901.
4 Measure the resistance between the gas dis-
charge headlamp relay, connector C901, pin 3,
circuit 15S-LE23A (GN/WH), BJB side and
fuse F18 (BJB).

• Is the resistance less than 2 ohms?

→ Yes
GO to C20
→ No
REPAIR the break in circuit 15S-LE23A
(GN/OG) between the gas discharge head-
lamp relay and fuse F18 (BJB) with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
C20: CHECK THE CIRCUIT TO FUSE F18 (BJB)
1 Disconnect Right-hand headlamp C1147.

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417-01-23 Exterior Lighting 417-01-23

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Key in ON position.
3 Switch on the dipped beam.
4 Measure the voltage between the right-hand
headlamp, connector C1147, pin 14, circuit
15S-LE23 (GN/WH), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to C21
→ No
REPAIR the break in circuit 15S-LE23
(GN/WH) between fuse F18 (BJB) and the
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
C21: CHECK THE GROUND CONNECTION OF THE HEADLAMP
1 Key in OFF position.
2 Measure the resistance between right-hand
headlamp, connector C1147, pin 11, circuit 31-
LE30 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE30 (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.

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417-01-24 Exterior Lighting 417-01-24

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST D: MAIN BEAM IS COMPLETELY INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE VOLTAGE AT THE WORKING CIRCUIT OF THE MAIN BEAM RELAY
1 Key in OFF position.
2 Disconnect Main beam relay C915.
3 Measure the voltage between the main beam
relay, connector C915, pin 3, CJB side and
ground.

• Is battery voltage indicated?

→ Yes
GO to D2
→ No
REPAIR the open circuit between fuse F7
(CJB) and the main beam relay (BJB) with
the aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
D2: CHECK THE VOLTAGE AT THE CONTROL CIRCUIT OF THE MAIN BEAM RELAY
1 Key in ON position.
2 Switch on the dipped beam and main beam.
3 Measure the voltage between the main beam
relay, connector C915, pin 2, CJB side and
ground.

• Is battery voltage indicated?

→ Yes
GO to D5
→ No
GO to D3
D3: CHECK THE CONTROL CIRCUIT OF THE MAIN BEAM RELAY
1 Key in OFF position.
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417-01-25 Exterior Lighting 417-01-25

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Turn signal switch C529.
3 Measure the resistance between the main
beam relay, connector C915, pin 2, CJB side
and the turn signal switch, connector C529, pin
7, circuit 15S-LE12A (GN/YE), wiring harness
side.

• Is the resistance less than 2 ohms?

→ Yes
GO to D4
→ No
REPAIR the open circuit between the turn
signal switch and the main beam relay with
the aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
D4: CHECK THE CIRCUIT BETWEEN THE LIGHT SWITCH AND THE TURN SIGNAL SWITCH
1 Disconnect Light switch (C478).
2 Measure the resistance between the light
switch, connector C478, pin 6, circuit 15S-
LE10 (GN/OG), wiring harness side and the
turn signal switch, connector C529, pin 8, cir-
cuit 15S-LE10 (GN/OG), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
RENEW the turn signal switch. CHECK the
operation of the system.
→ No
REPAIR the break in circuit 15S-LE10
(GN/OG) between the light switch and the
turn signal switch with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
D5: CHECK THE MAIN BEAM RELAY GROUND CONNECTION
1 Key in OFF position.

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417-01-26 Exterior Lighting 417-01-26

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the main
beam relay, connector C915, pin 1, CJB side
and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to D6
→ No
REPAIR the open circuit between the main
beam relay and ground connection G200
with the aid of the Wiring Diagrams, if nec-
essary RENEW the central junction box
(CJB). CHECK the operation of the sys-
tem.
D6: CHECK THE MAIN BEAM RELAY
1 Switch on the dipped beam and main beam.
2 Connect a bridging cable to the main beam
relay (CJB), connector C915, between pin 3
and pin 5, CJB side.

3 Key in ON position.
4 Check the main beams.
• Are the main beams illuminated?
→ Yes
INSTALL a new main beam relay. CHECK
the operation of the system.
→ No
RENEW the central junction box (CJB).
CHECK the operation of the system.

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417-01-27 Exterior Lighting 417-01-27

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E: ONE MAIN BEAM INOPERATIVE

CONDITIONS DETAILS/RESULTS/ACTIONS
E1: DETERMINE THE INOPERATIVE LAMP
1 Key in ON position.
2 Switch on the dipped beam and main beam.
3 Check main beams.
• Is the left-hand main beam inoperative?
→ Yes
GO to E2
→ No
Right-hand main beam inoperative:
GO to E6
E2: CHECK FUSE F85 (CJB)
1 Key in OFF position.
2 CHECK Fuse F85 (CJB).
3 Check fuse F85 (7,5 A).
• Is the fuse OK?
→ Yes
GO to E3
→ No
INSTALL a new fuse F85 (7,5 A). If the
fuse blows again, LOCATE and RECTIFY
the short to ground using the wiring dia-
grams. CHECK the operation of the sys-
tem.
E3: CHECK THE CENTRAL JUNCTION BOX (CJB).
1 Connect Fuse F85 (CJB).
2 Key in ON position.
3 Switch on the dipped beam and main beam.
4 Measure the voltage between fuse F85 (7.5 A)
and ground.
• Is battery voltage indicated?
→ Yes
Vehicles with conventional headlamps:
GO to E4
Vehicles with gas discharge headlamps:
GO to E10
→ No
REPAIR and if necessary RENEW the cen-
tral junction box (CJB). CHECK the opera-
tion of the system.
E4: CHECK THE CIRCUIT TO FUSE F85 (CJB)
1 Key in OFF position.
2 Disconnect Left-hand headlamp C146.
3 Key in ON position.
4 Switch on the dipped beam and main beam.

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417-01-28 Exterior Lighting 417-01-28

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between left-hand head-
lamp, connector C146, pin 2, circuit 15S-LE15
(GN/BK), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to E5
→ No
REPAIR the open circuit between fuse F85
(CJB) and the left-hand headlamp with the
aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
E5: CHECK THE GROUND CIRCUIT OF THE LEFT-HAND HEADLAMP
1 Key in OFF position.
2 Measure the resistance between left-hand
headlamp, connector C146, pin 6, circuit 31-
LE31A (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE31A (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
E6: CHECK FUSE F86 (CJB)
1 Key in OFF position.
2 CHECK Fuse F86 (CJB).
3 Check fuse F86 (7,5 A).

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417-01-29 Exterior Lighting 417-01-29

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the fuse OK?

→ Yes
GO to E7
→ No
INSTALL a new fuse F86 (7,5 A). If the
fuse blows again, LOCATE and RECTIFY
the short to ground using the wiring dia-
grams. CHECK the operation of the sys-
tem.
E7: CHECK THE CENTRAL JUNCTION BOX (CJB)
1 Connect Fuse F86 (CJB).
2 Key in ON position.
3 Switch on the dipped beam and main beam.
4 Measure the voltage between fuse F86 (7.5 A)
and ground.
• Is battery voltage indicated?
→ Yes
Vehicles with conventional headlamps:
GO to E8
Vehicles with gas discharge headlamps:
GO to E12
→ No
REPAIR and if necessary RENEW the cen-
tral junction box (CJB). CHECK the opera-
tion of the system.
E8: CHECK THE CIRCUIT TO FUSE F86 (CJB)
1 Key in OFF position.
2 Disconnect Right-hand headlamp C147.
3 Key in ON position.
4 Switch on the dipped beam and main beam.
5 Measure the voltage between right-hand head-
lamp, connector C147, pin 2, circuit 15S-LE22
(GN/OG), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to E9
→ No

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417-01-30 Exterior Lighting 417-01-30

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit between fuse F86
(CJB) and the right-hand headlamp with the
aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
E9: CHECK THE GROUND CIRCUIT OF THE RIGHT-HAND HEADLAMP
1 Key in OFF position.
2 Measure the resistance between right-hand
headlamp, connector C147, pin 6, circuit 31-
LE30A (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE31A (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
E10: CHECK THE CIRCUIT TO FUSE F85 (CJB)
1 Disconnect Left-hand headlamp C1146.
2 Key in ON position.
3 Switch on the dipped beam and main beam.
4 Measure the voltage between left-hand head-
lamp, connector C1146 1, circuit 15S-LE15
(GN/BK), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to E11
→ No

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417-01-31 Exterior Lighting 417-01-31

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit between fuse F85
(CJB) and the left-hand headlamp with the
aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
E11: CHECK THE GROUND CIRCUIT OF THE LEFT-HAND HEADLAMP
1 Key in OFF position.
2 Measure the resistance between left-hand
headlamp, connector C1146, pin 7, circuit 31-
LE31A (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand headlamp. CHECK the operation of
the system.
→ No
REPAIR the break in circuit 31-LE31A (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
E12: CHECK THE CIRCUIT TO FUSE F86 (CJB)
1 Key in OFF position.
2 Disconnect Right-hand headlamp C1147.
3 Key in ON position.
4 Switch on the dipped beam and main beam.
5 Measure the voltage between right-hand head-
lamp, connector C1147 1, circuit 15S-LE22
(GN/OG), harness side and ground.

• Is battery voltage indicated?

→ Yes

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417-01-32 Exterior Lighting 417-01-32

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to E13
→ No
REPAIR the open circuit between fuse F86
(CJB) and the right-hand headlamp with the
aid of the Wiring Diagrams, if necessary
RENEW the central junction box (CJB).
CHECK the operation of the system.
E13: CHECK THE GROUND CIRCUIT OF THE RIGHT-HAND HEADLAMP
1 Key in OFF position.
2 Measure the resistance between right-hand
headlamp, connector C1147 7, circuit 31-
LE30A (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the head-
lamp. CHECK the operation of the system.
→ No
REPAIR the break in circuit 31-LE31A (BK)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
PINPOINT TEST F: HEADLAMPS ON CONTINUOUSLY
CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK WHETHER THE MAIN OR DIPPED BEAMS ARE ON CONTINUOUSLY
1 Switch off the DIPPED BEAM and the TURN
SIGNAL LAMPS.
2 Check the main beams.
• Are the main beams illuminated?
→ Yes
GO to F2
→ No
Vehicles with conventional headlamps:
GO to F7
Vehicles with gas discharge headlamps:
GO to F13
F2: CHECK THE TURN SIGNAL SWITCH
1 Key in OFF position.
2 Disconnect Turn signal switch C529.
3 Check the main beams.

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417-01-33 Exterior Lighting 417-01-33

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the main beams illuminated?

→ Yes
GO to F3
→ No
RENEW the turn signal switch. CHECK the
operation of the system.
F3: CHECK THE MAIN BEAM RELAY
1 Disconnect Main beam relay C915.
2 Check main beams.
• Are the main beams illuminated?
→ Yes
GO to F4
→ No
GO to F6
F4: CHECK THE CIRCUIT TO FUSE F86 (CJB)
1 Disconnect Fuse F86 (CJB).
2 Check the main beam at the right-hand side.
• Is the main beam at the right-hand side illumi-
nated?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit between fuse F86
(CJB) and the right-hand headlamp with the
aid of the Wiring Diagrams, and if neces-
sary RENEW the central junction box (CJB).
CHECK the operation of the system.
→ No
GO to F5
F5: CHECK THE CIRCUIT TO FUSE F85 (CJB)
1 Disconnect Fuse F85 (CJB).
2 Check the main beam at the left-hand side.
• Is the main beam at the left-hand side illumi-
nated?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit between fuse F85
(CJB) and the left-hand headlamp with the
aid of the Wiring Diagrams, and if neces-
sary RENEW the central junction box (CJB).
CHECK the operation of the system.
→ No
LOCATE and RECTIFY the short to battery
voltage in the circuit between the main
beam relay and fuses F85, F86 (CJB) with
the aid of the Wiring Diagrams, and if nec-
essary RENEW the central junction box
(CJB). CHECK the operation of the sys-
tem.

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417-01-34 Exterior Lighting 417-01-34

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
F6: CHECK THE CONTROL CIRCUIT OF THE MAIN BEAM RELAY FOR A SHORT TO BATTERY
VOLTAGE
1 Measure the voltage between the main beam
relay, connector C915, pin 2, CJB side and
ground.

• Is battery voltage indicated?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuits connected to sol-
dered connection S132 with the aid of the
Wiring Diagrams, and if necessary renew
the central junction box (CJB). CHECK the
operation of the system.
→ No
INSTALL a new main beam relay. CHECK
the operation of the system.
F7: CHECK THE LIGHT SWITCH.
1 Disconnect Light switch (C478).
2 Check the dipped beams.
• Are the dipped beams illuminated?
→ Yes
GO to F8
→ No
Renew the light switch. CHECK the opera-
tion of the system.
F8: CHECK THE DIPPED BEAM RELAY
1 Disconnect Dipped beam relay C901.
2 Check the dipped beams.
• Are the dipped beams illuminated?
→ Yes
GO to F9
→ No
GO to F11
F9: CHECK THE CIRCUIT TO FUSE F18 (BJB)
1 Disconnect Fuse F18 (BJB).
2 Check the dipped beam at the right-hand side.
• Is the dipped beam at the right-hand side illu-
minated?

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417-01-35 Exterior Lighting 417-01-35

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit 15S-LE23 (GN/WH)
between fuse F18 (BJB) and the right-hand
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
→ No
GO to F10
F10: CHECK THE CIRCUIT TO FUSE F16 (CJB)
1 Disconnect Fuse F16 (BJB).
2 Check the dipped beam at the left-hand side.
• Is the dipped beam at the left-hand side illumi-
nated?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit 15S-LE16 (GN/OG)
between fuse F16 (BJB) and the left-hand
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
→ No
GO to F11
F11: CHECK THE CONTROL CIRCUIT OF THE DIPPED BEAM RELAY FOR A SHORT TO
BATTERY VOLTAGE
1 Measure the voltage between dipped beam
relay, connector C901, pin 2, circuit15S-LE19
(GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to F12
→ No
INSTALL a new dipped beam relay. CHECK
the operation of the system.
F12: NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE BETWEEN THE
LIGHT SWITCH AND THE DIPPED BEAM RELAY
1 Disconnect Fuse F95 (CJB).

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417-01-36 Exterior Lighting 417-01-36

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between dipped beam
relay, connector C901, pin 2, circuit15S-LE19
(GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuits connected to the out-
put of fuse F95 (CJB) with the aid of the
Wiring Diagrams, and if necessary renew
the central junction box (CJB). CHECK the
operation of the system.
→ No
LOCATE and RECTIFY the short to battery
voltage in the circuits connected to the in-
put of fuse F95 (CJB) with the aid of the
Wiring Diagrams, and if necessary renew
the central junction box (CJB). CHECK the
operation of the system.
F13: READ OUT THE FAULT MEMORY
1 Connect the diagnostic tool.
2 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.
→ No
GO to F14
F14: CHECK THE LIGHT SWITCH
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Check the dipped beams.
• Are the dipped beams illuminated?
→ Yes
GO to F15
→ No
Renew the light switch. CHECK the opera-
tion of the system.

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417-01-37 Exterior Lighting 417-01-37

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
F15: CHECK THE GAS DISCHARGE HEADLAMP RELAY
1 Disconnect Gas discharge headlamp relay
C901.
2 Check the dipped beams.
• Are the dipped beams illuminated?
→ Yes
GO to F16
→ No
GO to F18
F16: CHECK THE CIRCUIT TO FUSE F18 (BJB)
1 Disconnect Fuse F18 (BJB).
2 Check the dipped beam at the right-hand side.
• Is the dipped beam at the right-hand side illu-
minated?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit 15S-LE23 (GN/WH)
between fuse F18 (BJB) and the right-hand
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
→ No
GO to F17
F17: CHECK THE CIRCUIT TO FUSE F16 (BJB)
1 Disconnect Fuse F16 (BJB).
2 Check the dipped beam at the left-hand side.
• Is the dipped beam at the left-hand side illumi-
nated?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit 15S-LE16 (GN/OG)
between fuse F16 (BJB) and the left-hand
headlamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
→ No
LOCATE and RECTIFY the short to battery
voltage in the circuit 15S-LE16A (GN/OG)
or 15S-LE23A (GN/WH) between the gas
discharge headlamp relay and fuses F16,
F18 (BJB) with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.

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417-01-38 Exterior Lighting 417-01-38

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
F18: CHECK THE CONTROL CIRCUIT OF THE GAS DISCHARGE HEADLAMP RELAY
1 Measure the voltage between gas discharge
headlamp relay, connector C901, pin 2, circuit
15S-LE19 (GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
GO to F19
→ No
INSTALL a new gas discharge headlamp re-
lay. CHECK the operation of the system.
F19: NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE BETWEEN THE
LIGHT SWITCH AND THE GAS DISCHARGE HEADLAMP RELAY
1 Disconnect Fuse F95 (CJB).
2 Measure the voltage between gas discharge
headlamp relay, connector C901, pin2, circuit
15S-LE19 (GN/BU), BJB side and ground.

• Is battery voltage indicated?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuits connected to the out-
put of fuse F95 (CJB) with the aid of the
Wiring Diagrams, and if necessary renew
the central junction box (CJB). CHECK the
operation of the system.
→ No

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417-01-39 Exterior Lighting 417-01-39

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the short to battery
voltage in the circuits connected to the in-
put of fuse F95 (CJB) with the aid of the
Wiring Diagrams, and if necessary renew
the central junction box (CJB). CHECK the
operation of the system.

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417-01-40 Exterior Lighting 417-01-40

DIAGNOSIS AND TESTING

Stoplamps

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Inspection and Verification
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electrical damage.
device
Visual Check
Electrical
• Fuse(s).
Terminal probe kit • Bulb(s).
29-011 A • Rear lamp assembly.
• Electrical connector(s).
• Switch(es).
• Wiring harness.
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.

Condition Possible Sources Action

• All stop lamps inoperative • Fuse(s). • GO to Pinpoint Test G
• Circuit(s).
• Stop lamp switch.
• Central junction box (CJB).
• One or more stop lamps are in- • Circuit(s). • GO to Pinpoint Test H
operative • Rear lamp assembly(s).
• High mounted stop lamp.
• Stop lamps continuously lit • Circuit(s). • GO to Pinpoint Test I
• Stop lamp switch.
• Powertrain control module
(PCM).
• ABS module
• Cruise control module.
• Transmission selector lever
assembly
• Trailer interface (TI) module
• Central junction box (CJB)

Pinpoint Tests
PINPOINT TEST G: ALL STOP LAMPS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
G1: TEST THE VOLTAGE SUPPLY AT THE STOP LAMP SWITCH
1 Key in OFF position.

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417-01-41 Exterior Lighting 417-01-41

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Stop lamp switch C523.
3 Key in ON position.
4 Check the voltage between the stoplamp
switch, connector C523, pin 3, circuit 15-LG23
(GN/WH), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to G4
→ No
GO to G2
G2: CHECK POWER SUPPLY TO FUSE F93 (CJB)
1 Key in ON position.
2 Test voltage between fuse F93 (10 A) and
ground.
• Is battery voltage indicated?
→ Yes
GO to G3
→ No
REPAIR the power supply to fuse F93 using
the wiring diagrams, RENEW the central
junction box (CJB) if necessary. TEST the
system for normal operation.
G3: CHECK CIRCUIT 15-LG23 (GN/WH)
1 Key in OFF position.
2 Disconnect CJB C509.
3 Measure resistance between CJB, connector
C509, pin 9, circuit 15-LG23 (GN/WH) or 15-
LE2 (GN/BU) (vehicles with gas discharge
lamps from 10/2001), wiring harness side and
stop lamp switch, connector C523, pin 3, circuit
15-LG23 (GN/WH), wiring harness side.

• Is the resistance less than 2 ohms?

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417-01-42 Exterior Lighting 417-01-42

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
→ No
REPAIR open circuit 15-LG23 (GN/WH) or
15-LE2 (GN/BU) between fuse F93 and
stop lamp switch using the wiring diagrams.
TEST the system for normal operation.
G4: CHECK THE STOP LAMP SWITCH
1 Key in OFF position.
2 Using a test cable at the stop lamp switch,
bridge connector C523, pin 1, circuit 15(S)-
LG23 (GN/WH) and pin 3, circuit 15-LG23
(GN/WH), wiring harness side.

3 Key in ON position.
• Are the stop lamps illuminated?
→ Yes
CHECK and if necessary RENEW the stop
lamp switch. TEST the system for normal
operation.
→ No
GO to G5
G5: CHECK THE VOLTAGE SUPPLY CIRCUIT OF THE CENTRAL JUNCTION BOX (CJB).
1 Key in OFF position.
2 Disconnect C505.
3 Using a test cable at the stop lamp switch,
bridge connector C523, pin 1, circuit 15(S)-
LG23 (GN/WH) and pin 3, circuit 15-LG23
(GN/WH), wiring harness side.

4 Key in ON position.

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417-01-43 Exterior Lighting 417-01-43

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Check the voltage between the CJB, connector
C505, pin 7, circuit 15S-LG23 (GN/WH), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
→ No
REPAIR open circuit 15S-LG23 (GN/WH)
between stop lamp switch and CJB using
the wiring diagrams. TEST the system for
normal operation.
PINPOINT TEST H: ONE OR MORE STOP LAMPS ARE INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
H1: DETERMINE THE INOPERATIVE LAMP
1 Key in ON position.
2 Depress the brake pedal.
3 Check the stop lamps.
• Is the high mounted stop lamp inoperative?
→ Yes
GO to H2
→ No
Stop lamps inoperative, wagon: GO to H4
Left-hand stop lamp inoperative, 4-/5-door
without trailer socket: GO to H5
Left- and right-hand stop lamps inoperative,
4-/5-door: GO to H4
Left-hand stop lamp inoperative, 4-/5-door
with trailer socket: GO to H4
Stop lamp right-hand side is inoperative:
GO to H6
H2: CHECK THE VOLTAGE SUPPLY AT THE ADDITIONAL HIGH-MOUNTED STOP LAMP
1 Key in OFF position.
2 Disconnect High mounted stop lamp C700.
3 Key in ON position.
4 Depress the BRAKE PEDAL and keep it de-
pressed.

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417-01-44 Exterior Lighting 417-01-44

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the additional
high-mounted stop lamp, connector C700, pin
2, circuit 15S-LG6 (GN/YE), wiring harness
side and ground.

• Is battery voltage indicated?

→ Yes
GO to H3
→ No
REPAIR break in circuit 15S-LG6(A)
(GN/YE), between CJB and high mounted
stop lamp, using the wiring diagrams, if
necessary RENEW the central junction box
(CJB). TEST the system for normal opera-
tion.
H3: CHECK GROUND CONNECTION OF CIRCUIT 31-LG6 (BK)
1 Key in OFF position.
2 Measure the resistance between the high
mounted stop lamp, connector C700, pin 1,
circuit 31-LG6 (BK), wiring harness side and
ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the addi-
tional high-mounted stop lamp. TEST the
system for normal operation.
→ No
REPAIR break in circuit 31-LG6 (BK) be-
tween high-mounted stop lamp and ground
G300 or G200 (4-/5-door) using the wiring
diagrams. TEST the system for normal op-
eration.

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417-01-45 Exterior Lighting 417-01-45

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
H4: CHECK THE VOLTAGE SUPPLY AT THE LEFT-HAND STOP LAMP.
1 Key in OFF position.
2 Disconnect Left-hand stop lamp.
- C540 (4-/5-door without trailer socket)
- C2005 (4-/5-door with trailer socket)
- C540a Wagon
3 Key in ON position.
4 Depress the BRAKE PEDAL and keep it de-
pressed.
5 Test the voltage between the left-hand rear
lamp assembly:
- 4-/5-door without trailer socket: Connector
C540, pin 3, circuit 15S-LG14 (GN/RD),
wiring harness side and ground.
- 4-/5-door with trailer socket: Connector
C2005, pin 3, circuit (BK/RD), wiring harness
side and ground.
- Wagon: Connector C540a, pin 2, circuit 15S-
LG14 (GN/RD), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to H5
→ No
REPAIR break in circuit 15S-LG14 (GN/RD)
or (BK/RD), between CJB and rear lamp
assembly using the wiring diagrams, if nec-
essary RENEW the central junction box
(CJB). TEST the system for normal opera-
tion.
H5: CHECK THE GROUND CONNECTION OF THE LEFT-HAND STOP LAMP
1 Key in OFF position.
2 Measure the resistance between the left-hand
rear lamp assembly:
- 4-/5-door without trailer socket: Connector
C540, pin 6, circuit 31-LF11 (BK), wiring
harness side and ground.
- 4-/5-door with trailer socket: Connector
C2005, pin 6, circuit (BN), wiring harness
side and ground.
- Wagon: Connector C540a, pin 1, circuit 31-
LG14 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes

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417-01-46 Exterior Lighting 417-01-46

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK and if necessary RENEW the rear
lamp assembly. TEST the system for nor-
mal operation.
→ No
REPAIR open circuit 31-LF11 (BK) or 31-
LG14 (BK), between rear lamp assembly
and ground G300, using the wiring dia-
grams. TEST the system for normal opera-
tion.
H6: CHECK THE VOLTAGE SUPPLY OF THE RIGHT-HAND REAR LAMP ASSEMBLY
1 Key in OFF position.
2 Disconnect Right-hand rear lamp assembly.
- C541 (4-/5-door without trailer socket)
- C2007 (4-/5-door with trailer socket)
- C541a Wagon
3 Key in ON position.
4 Depress the BRAKE PEDAL and keep it de-
pressed.
5 Test the voltage between the right-hand rear
lamp assembly:
- 4-/5-door without trailer socket: Connector
C541, pin 3, circuit 15S-LG21 (GN/BK),
wiring harness side and ground.
- 4-/5-door with trailer socket: Connector
C2007, pin 3, circuit (GN), wiring harness
side and ground.
- Wagon: Connector C541a, pin 2, circuit 15S-
LG14 (GN/RD), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to H7
→ No
REPAIR break in circuit 15S-LG21 (GN/BK),
15S-LG14 (GN/RD) or (GN), between CJB
and rear lamp assembly using the wiring
diagrams, if necessary RENEW the central
junction box (CJB). TEST the system for
normal operation.
H7: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP ASSEMBLY
1 Key in OFF position.

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417-01-47 Exterior Lighting 417-01-47

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the right-hand
rear lamp assembly:
- 4-/5-door without trailer socket: Connector
C541, pin 6, circuit 31-LF20 (BK), wiring
harness side and ground.
- 4-/5-door with trailer socket: Connector
C2007, pin 6, circuit (GN), wiring harness
side and ground.
- Wagon: Connector C541a, pin 1, circuit 31-
LG14 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the rear
lamp assembly. TEST the system for nor-
mal operation.
→ No
REPAIR open circuit 31-LF20 (BK) or 31-
LG14 (BK), between rear lamp assembly
and ground G300 (4-/5-door) or G205
(wagon), using the wiring diagrams. TEST
the system for normal operation.
PINPOINT TEST I: STOP LAMPS CONTINUOUSLY LIT
CONDITIONS DETAILS/RESULTS/ACTIONS
I1: CHECK THE STOP LAMP SWITCH
1 Key in OFF position.
2 Disconnect Stop lamp switch C523.
3 Key in ON position.
4 Check the stop lamps.
• Are the stop lamps illuminated?
→ Yes
GO to I2
→ No
INSTALL a new stop lamp switch. TEST
the system for normal operation.
I2: NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE
1 Key in OFF position.
2 Disconnect CJB (C506).
3 Key in ON position.
4 Check the stop lamps.
• Does only the high-mounted stop lamp illumi-
nate?
→ Yes

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417-01-48 Exterior Lighting 417-01-48

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
With manual transmission: REPAIR circuit
15S-LG6(A) (GN/YE), shorted to battery
positive, using the wiring diagrams. TEST
the system for normal operation.
With automatic transmission: REPAIR circuit
15S-LG6 (GN/YE) or 15S-TA33 (GN/WH),
shorted to battery positive, using the wiring
diagrams. If necessary, CHECK the trans-
mission selector lever assembly, RENEW it
if required. TEST the system for normal
operation.
→ No
Wagon without trailer socket, left- or right-
hand stop lamp lit continuously: REPAIR
circuit 15S-LG21 (GN/BK) or 15S-LG14
(GN/RD), shorted to battery positive, be-
tween CJB and rear lamp assembly, using
the wiring diagrams. TEST the system for
normal operation.
4-/5-door without trailer, right- and left-hand
stop lamps lit continuously: REPAIR circuit
15S-LG14 (GN/RD) or 15S-LG21 (GN/BK),
shorted to battery positive, between CJB
and rear lamp assembly, using the wiring
diagrams. TEST the system for normal op-
eration.
Vehicles with trailer socket, right- and left-
hand stop lamps lit continuously: GO to I8
Stop lamps do not illuminate: GO to I3
I3: CHECK THE CENTRAL JUNCTION BOX (CJB)
1 Key in OFF position.
2 Disconnect C505.
3 Connect C506.
4 Key in ON position.
5 Check the stop lamps.
• Are the stop lamps illuminated?
→ Yes
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
→ No
GO to I4

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
I4: CHECK CIRCUITS FOR SHORT TO BATTERY POSITIVE
1 Check the voltage between the CJB, connector
C505, pin 6, circuit 15S-RE13 (GN/RD), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to I5
→ No
Vehicles with cruise control system:
GO to I7
Vehicles without cruise control system:
REPAIR circuit 15S-LG23 (GN/WH),
shorted to battery positive, using the wiring
diagrams. TEST the system for normal op-
eration.
I5: CHECK CIRCUITS FOR SHORT TO BATTERY POSITIVE
1 Key in OFF position.
2 Disconnect PCM C100.
3 Disconnect ABS module C103.
4 Key in ON position.
5 Check the voltage between the CJB, connector
C505, pin 6, circuit 15S-RE13 (GN/RD), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR circuit 15S-CF58 (GN/OG) or 15S-
RE13 (GN/RD), shorted to battery positive,
using the wiring diagrams. TEST the sys-
tem for normal operation.
→ No
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417-01-50 Exterior Lighting 417-01-50

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to I6
I6: CHECK ABS MODULE
1 Key in OFF position.
2 Connect ABS module C103.
3 Key in ON position.
4 Check the voltage between the CJB, connector
C505, pin 6, circuit 15S-CF58 (GN/OG), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK ABS module, RENEW it if neces-
sary. TEST the system for normal opera-
tion.
→ No
CHECK PCM module, RENEW it if neces-
sary. TEST the system for normal opera-
tion.
I7: CHECK CIRCUITS FOR SHORT TO BATTERY POSITIVE
1 Key in OFF position.
2 Disconnect PCM C100 (diesel).
3 Disconnect Cruise control system C175 (vehi-
cles with a petrol engine).
4 Key in ON position.
5 Check the voltage between the CJB, connector
C505, pin 7, circuit 15S-LG23 (GN/WH), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes

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417-01-51 Exterior Lighting 417-01-51

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 15S-LG23 (GN/WH), 15S-
PG7 (GN/BU) or 15S-PG17 (GN/BU)
shorted to battery positive, using the wiring
diagrams. TEST the system for normal op-
eration.
→ No
Diesel: CHECK PCM module, RENEW it if
necessary. TEST the system for normal
operation.
Petrol engine: CHECK and if necessary
RENEW cruise control system. TEST the
system for normal operation.
I8: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Connect Trailer interface (TI) module C2000.
3 Key in ON position.
4 Check the voltage between the CJB, connector
C506, pin 2, circuit 15S-LG14 (GN/RD), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR circuit 15S-LG14 (GN/RD), 15S-
LG21 (GN/BK), (BK/RD) or (GN) shorted to
battery positive, between CJB and rear lamp
assembly, using the wiring diagrams.
TEST the system for normal operation.
→ No
CHECK the trailer interface (TI), RENEW it
if necessary. TEST the system for normal
operation.

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417-01-52 Exterior Lighting 417-01-52

DIAGNOSIS AND TESTING

Turn Signal and Hazard Lamps

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Inspection and Verification
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electrical damage.
device
Visual Check
Electrical
• Fuse(s).
Terminal probe kit • Bulb(s).
29-011 A • Electrical connector(s).
• Switch(es).
• Wiring harness.
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Acoustic turn signal is inopera- • Circuit(s). • GO to Pinpoint Test J
tive • Turn signal switch
• Generic electronic module
(GEM).
• Hazard warning lights are com- • Fuse(s). • GO to Pinpoint Test K
pletely inoperative • Circuit(s).
• Hazard warning lamp switch
• Generic electronic module
(GEM).
• Turn signal lamps are inopera- • Circuit(s). • GO to Pinpoint Test L
tive • Turn signal switch
• Generic electronic module
(GEM).
• The left- or right-hand turn sig- • Circuit(s). • GO to Pinpoint Test M
nals are inoperative. • Turn signal switch
• Generic electronic module
(GEM).

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417-01-53 Exterior Lighting 417-01-53

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• One or more turn signal lamps • Circuit(s). • GO to Pinpoint Test N
are inoperative • Bulb
• Turn signal switch
• Generic electronic module
(GEM).
• Front turn signal lamp
• Headlamps
• Tail Lamp Assembly
• Trailer switch interface (SI)
module
• One or more turn signal lamps • Circuit(s). • GO to Pinpoint Test O
illuminate/flash continually • Turn signal lamp switch
• Generic electronic module
(GEM).
• Instrument cluster.
• Trailer switch interface (SI)
module

Pinpoint Tests
PINPOINT TEST J: ACOUSTIC TURN SIGNAL IS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
J1: CHECK SIGNAL FROM TURN SIGNAL LAMP SWITCH
1 Key in OFF position.
2 Disconnect Turn signal lamp switch C529.
3 Connect a bridging cable between turn signal
lamp switch, connector C529, pin 1, circuit
91S-LG27B (BK/GN), wiring harness side and
pin 2, circuit 91-LG27 (BK/GN), wiring harness
side.

4 Key in ON position.

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417-01-54 Exterior Lighting 417-01-54

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between turn signal lamp
switch, connector C529, pin 4, circuit 29S-
LG43 (OG/WH), wiring harness side and
ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to J3
→ No
GO to J2
J2: CHECK CIRCUIT 29S-LG43 (OG/WH)
1 Key in OFF position.
2 Disconnect GEM C430.
3 Measure resistance between GEM, connector
C430, pin 22, circuit 29S-LG43 (OG/WH), wir-
ing harness side and turn signal lamp switch,
connector C529, pin 4, circuit 29S-LG43
(OG/WH), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 29S-LG43 (OG/WH), be-
tween GEM and turn signal lamp switch,
using the wiring diagrams. TEST the sys-
tem for normal operation.
J3: CHECK CIRCUIT 31-LG43 (BK)
1 Key in OFF position.

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417-01-55 Exterior Lighting 417-01-55

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the turn sig-
nal lamp switch, connector C529, pin 5, circuit
31-LG43 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the turn
signal lamp switch. TEST the system for
normal operation
→ No
REPAIR circuit 31-LG43 (BK), between turn
signal lamp switch and ground G204, using
the wiring diagrams. TEST the system for
normal operation.
PINPOINT TEST K: HAZARD WARNING LIGHTS ARE COMPLETELY INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
K1: CHECK GROUND CONNECTION OF THE HAZARD WARNING SWITCH
1 Key in OFF position.
2 Disconnect GEM C429.
3 Switch on the hazard warning lights.
4 Measure the resistance between GEM, con-
nector C429, pin 23, circuit 91S-LG8 (BK/OG),
harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No

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417-01-56 Exterior Lighting 417-01-56

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to K2
K2: CHECK CIRCUIT 91S-LG8 (BK/OG)
1 Disconnect Hazard warning lamp switch C438.
2 Measure resistance between GEM, connector
C429, pin 23, circuit 91S-LG8 (BK/OG), wiring
harness side and hazard warning switch, con-
nector C438, pin 2, circuit 91S-LG8 (BK/OG),
wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to K3
→ No
REPAIR circuit 91S-LG8 (BK/OG), between
hazard warning switch and GEM, using the
wiring diagrams. TEST the system for
normal operation.
K3: CHECK CIRCUIT 91-LG8 (BK/OG)
1 Measure the resistance between the hazard
warning lights switch, connector C438, pin 1,
circuit 91-LG8 (BK/OG), wiring harness side
and ground.

• Is the resistance less than 2 ohms?

→ Yes
TEST the hazard warning lamp switch,
RENEW it if necessary. TEST the system
for normal operation.
→ No
REPAIR circuit 91-LG8 (BK/OG), between
hazard warning switch and ground G203.
TEST the system for normal operation.

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417-01-57 Exterior Lighting 417-01-57

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST L: TURN SIGNAL LAMPS ARE INOPERATIVE

CONDITIONS DETAILS/RESULTS/ACTIONS
L1: CHECK GROUND CONNECTION OF TURN SIGNAL LAMP SWITCH
1 Key in OFF position.
2 Disconnect Turn signal lamp switch C529.
3 Measure the resistance between the turn sig-
nal lamp switch, connector C529, pin 2, circuit
91-LG27 (BK/GN), wiring harness side and
ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK turn signal lamp switch according to
the component tests in the wiring diagrams,
RENEW it if necessary. TEST the system
for normal operation. If the concern per-
sists, CHECK system using WDS, if neces-
sary RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 91-LG27 (BK/GN), between
turn signal lamp switch and ground G203,
using the wiring diagrams. TEST the sys-
tem for normal operation.
PINPOINT TEST M: THE LEFT- OR RIGHT-HAND TURN SIGNAL LAMPS ARE INOPERATIVE.
CONDITIONS DETAILS/RESULTS/ACTIONS
M1: DETERMINE THE FAULT CONDITION
1 Key in ON position.
2 Switch on the LEFT-HAND TURN SIGNAL.
• Are the left-hand turn signals inoperative?
→ Yes
GO to M2
→ No
GO to M3
M2: CHECK CIRCUIT 91S-LG27B (BK/GN)
1 Key in OFF position.
2 Disconnect GEM C429.
3 Switch on the RIGHT-HAND TURN SIGNAL.

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417-01-58 Exterior Lighting 417-01-58

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between GEM, con-
nector C429, pin 17, circuit 91S-LG27B
(BK/GN), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
CHECK turn signal lamp switch according to
the component tests in the wiring diagrams,
RENEW it if necessary. TEST the system
for normal operation.
If the concern persists, REPAIR circuit 91S-
LG27 (BK/GN), between turn signal lamp
switch and GEM, using the wiring diagrams.
TEST the system for normal operation.
M3: CHECK CIRCUIT 91S-LG27A (BK/GN)
1 Key in OFF position.
2 Disconnect GEM C429.
3 Switch on the RIGHT-HAND TURN SIGNAL.
4 Measure the resistance between GEM, con-
nector C429, pin 19, circuit 91S-LG27A
(BK/GN), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes

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417-01-59 Exterior Lighting 417-01-59

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
CHECK turn signal lamp switch according to
the component tests in the wiring diagrams,
RENEW it if necessary. TEST the system
for normal operation.
If the concern persists, REPAIR circuit 91S-
LG27A (BK/GN), between turn signal lamp
switch and GEM, using the wiring diagrams.
TEST the system for normal operation.
PINPOINT TEST N: ONE OR MORE TURN SIGNAL LAMPS ARE INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
N1: DETERMINE THE FAULT CONDITION
1 Determine the fault condition.
• Is one of the left-hand turn signal lamps inop-
erative?
→ Yes
GO to N2
→ No
One right-hand turn signal lamp is inopera-
tive: GO to N18
N2: DETERMINE THE FAULT CONDITION
1 Key in ON position.
2 Switch on the LEFT-HAND TURN SIGNAL.
3 Check front left-hand turn signal lamp.
• Is the front left-hand turn signal lamp inopera-
tive?
→ Yes
GO to N3
→ No
The left-hand turn signal side repeater lamp
is inoperative: GO to N5
The left-hand turn front signal lamp and side
repeater lamp are inoperative: GO to N7
The rear left-hand turn signal lamp is inop-
erative: GO to N8 (without trailer interface
socket) or GO to N11 (with trailer interface
socket)
The left-hand warning lamp in the instru-
ment cluster is inoperative: GO to N16
N3: CHECK VOLTAGE SUPPLY TO LEFT-HAND HEADLAMP
1 Key in OFF position.
2 Disconnect Left-hand headlamp C146 (con-
ventional headlamp) or C1146 (gas discharge
headlamp).
3 Key in ON position.

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417-01-60 Exterior Lighting 417-01-60

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Switch on the LEFT-HAND TURN SIGNAL.
5 Measure the voltage between the left-hand
headlamp, connector C146, pin 3 (conven-
tional headlamp), or connector C1146, pin 4
(gas discharge headlamp), circuit 49-LG11
(BU/OG), wiring harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N4
→ No
REPAIR circuit 49-LG11 (OG/BU), between
solder point S371 and headlamp, using the
wiring diagrams. TEST the system for
normal operation.
N4: CHECK CIRCUIT 31-LE31A (BK)
1 Key in OFF position.
2 Measure the resistance between the left-hand
headlamp, connector C146, pin 6 (conven-
tional headlamp), or connector C1146, pin 7
(gas discharge headlamp), circuit 31-LE31A
(BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand headlamp. TEST the system for nor-
mal operation.
→ No
REPAIR circuit 31-LG31A (BK), between
headlamp and ground G104, using the wir-
ing diagrams. TEST the system for normal
operation.
N5: CHECK THE POWER SUPPLY OF THE SIDE DIRECTION INDICATOR LAMP LH SIDE
1 Key in OFF position.

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417-01-61 Exterior Lighting 417-01-61

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Side direction indicator lamp LH
C163.
3 Key in ON position.
4 Switch on the LEFT-HAND TURN SIGNAL.
5 Measure the voltage between the left-hand
side turn repeater lamp, connector C163, pin
2, circuit 49-LG13 (BU/RD), wiring harness
side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N6
→ No
REPAIR circuit 49-LG13 (BU/RD), between
solder point S371 and side repeater lamp,
using the wiring diagrams. TEST the sys-
tem for normal operation.
N6: CHECK CIRCUIT 31-LG13 (BK)
1 Key in OFF position.
2 Measure the resistance between side direction
indicator lamp LH side, connector C163, pin 1,
circuit 31-LG13 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand side repeater lamp. TEST the system
for normal operation.
→ No

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417-01-62 Exterior Lighting 417-01-62

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 31-LG13 (BK), between left-
hand side repeater lamp and ground G104,
using the wiring diagrams. TEST the sys-
tem for normal operation.
N7: CHECK CIRCUIT 49-LG1 (BU)
1 Key in OFF position.
2 Disconnect Side direction indicator lamp LH
C163.
3 Disconnect GEM C426.
4 Measure the resistance between side direction
indicator lamp LH side, connector C163, pin 2,
circuit 49-LG13 (BU/RD), harness side and
GEM, connectorC426, pin 4, circuit 49-LG1
(BU), harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 49-LG1 (BU), between left-
hand side repeater lamp and GEM, using
the wiring diagrams. TEST the system for
normal operation.
N8: CHECK THE POWER SUPPLY OF THE REAR LAMP ASSEMBLY LH SIDE
1 Key in OFF position.
2 Disconnect Left-hand rear lamp assembly
C540 (4-/5-door) or C540b (wagon).
3 Key in ON position.
4 Switch on the LEFT-HAND TURN SIGNAL.

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417-01-63 Exterior Lighting 417-01-63

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure voltage between left-hand rear lamp
assembly, connector C540, pin 2, circuit 49-
LG12 (BU) (4-/5-door) or connector C540b, pin
2, circuit 15S-LG12 (GN/YE) (wagon), wiring
harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N10
→ No
GO to N9
N9: CHECK CIRCUIT 49-LG12 (BU) OR 15S-LG12 (GN/YE)
1 Key in OFF position.
2 Disconnect GEM C427.
3 Disconnect Left-hand rear lamp assembly
C540 (4-/5-door) or C540b (wagon).
4 Measure resistance between left-hand rear
lamp assembly, connector C540, pin 2, circuit
49-LG12 (BU) (4-/5-door) or connector C540b,
pin 2, circuit 15S-LG12 (GN/YE) (wagon), wir-
ing harness side and GEM, connector C427,
pin 2, circuit 49-LG12 (BU), wiring harness
side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 49-LG12 (BU) or 15S-LG12
(GN/YE), between left-hand rear lamp as-
sembly and GEM, using the wiring dia-
grams. TEST the system for normal opera-
tion.

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417-01-64 Exterior Lighting 417-01-64

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
N10: CHECK CIRCUIT 31-LF11 (BK) OR 31-LG12 (BK)
1 Key in OFF position.
2 Disconnect Left-hand rear lamp assembly
C540 (4-/5-door) or C540b (wagon).
3 Measure resistance between left-hand rear
lamp assembly, connector C540, pin 6, circuit
31-LF11 (BK) (4-/5-door) or connector C540b,
pin 1, circuit 31-LG12 (BK) (wagon), wiring
harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand rear lamp assembly. TEST the sys-
tem for normal operation.
→ No
REPAIR circuit 31-LF11 (BK) or 31-LG12
(BK), between left-hand rear lamp assem-
bly and ground G300, using the wiring dia-
grams. TEST the system for normal opera-
tion.
N11: CHECK THE POWER SUPPLY OF THE REAR LAMP ASSEMBLY LH SIDE
1 Key in OFF position.
2 Disconnect Left-hand rear lamp assembly
C2005 (4-/5-door) or C540b (wagon).
3 Key in ON position.
4 Switch on the LEFT-HAND TURN SIGNAL.
5 Measure voltage between left-hand rear lamp
assembly, connector C2005, pin 2, circuit 31-
LF11 (GN/WH) (4-/5-door) or connector
C540b, pin 2, circuit 15S-LG12 (GN/YE)
(wagon), wiring harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?

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417-01-65 Exterior Lighting 417-01-65

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to N15
→ No
GO to N12
N12: CHECK CIRCUIT 49-LG12 (BU) OR (WH)
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Key in ON position.
4 Switch on the LEFT-HAND TURN SIGNAL.
5 Measure voltage between trailer switch inter-
face (SI) module, connector C2002, pin 5, cir-
cuit (WH), wiring harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N14
→ No
GO to N13
N13: CHECK CIRCUIT 49-LG12 (BU) OR (WH)
1 Key in OFF position.
2 Disconnect GEM C427.
3 Measure resistance between trailer switch in-
terface (SI) module, connector C2002, pin 5,
circuit (WH), wiring harness side and GEM,
connector C427, pin 2, circuit 49-LG12 (BU),
wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes

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417-01-66 Exterior Lighting 417-01-66

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit (WH) or 49-LG12 (BU), be-
tween trailer switch interface (SI) module
and GEM, using the wiring diagrams.
TEST the system for normal operation.
N14: CHECK CIRCUIT (GY/WH), 15S-LG12 (GN/YE) OR (GN/WH)
1 Key in OFF position.
2 Measure resistance between trailer switch in-
terface (SI) module, connector C2002, pin 8,
circuit (GN/WH) (4-/5-door) or (GY/WH)
(wagon), wiring harness side and left-hand
rear lamp assembly, connector C2005, pin 2,
circuit (GN/WH) (4-/5-door) or connector
C540b, pin 2, circuit 15S-LG12 (GN/YE)
(wagon), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK the trailer switch interface (SI)
module, if necessary RENEW it. TEST the
system for normal operation.
→ No
REPAIR break in circuit (GY/WH),
(GN/WH). or 15S-LG12 (GN/YE), between
trailer switch interface (SI) module and rear
lamp assembly, using the wiring diagrams.
TEST the system for normal operation.
N15: CHECK CIRCUIT (BN) OR 31-LG12 (BK)
1 Key in OFF position.
2 Measure resistance between left-hand rear
lamp assembly, connector C2005, pin 6, cir-
cuit (BN) (4-/5-door) or connector C540b, pin 1,
circuit 31-LG12 (BK) (wagon), wiring harness
side and ground.

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417-01-67 Exterior Lighting 417-01-67

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand rear lamp assembly. TEST the sys-
tem for normal operation.
→ No
REPAIR circuit (BN) or 31-LG12 (BK), be-
tween left-hand rear lamp assembly and
ground G300, using the wiring diagrams.
TEST the system for normal operation.
N16: CHECK THE POWER SUPPLY OF THE INSTRUMENT CLUSTER
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Key in ON position.
4 Switch on the LEFT-HAND TURN SIGNAL.
5 Measure the voltage between instrument clus-
ter, connector C449, pin18, circuit 49-LG15
(BU/BK), harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the in-
strument cluster. TEST the system for
normal operation.
→ No
GO to N17
N17: CHECK CIRCUIT 49-LG15 (BU/BK)
1 Key in OFF position.
2 Disconnect GEM C429.

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417-01-68 Exterior Lighting 417-01-68

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between instrument
cluster, connector C449, pin18, circuit 49-
LG15 (BU/BK), harness side and GEM, con-
nector C429, pin 3,circuit 49-LG15 (BU/BK),
harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 49-LG15 (BU/BK), between
instrument cluster and GEM, using the wir-
ing diagrams. TEST the system for normal
operation.
N18: DETERMINE THE FAULT CONDITION
1 Key in ON position.
2 Switch on the RIGHT-HAND TURN SIGNAL.
3 Check front right-hand turn signal lamp.
• Is the front right-hand turn signal lamp inop-
erative?
→ Yes
GO to N19
→ No
The right-hand turn signal side repeater
lamp is inoperative: GO to N21
The right-hand turn front signal lamp and
side repeater lamp are inoperative:
GO to N23
The rear right-hand turn signal lamp is inop-
erative: GO to N24 (without trailer inter-
face socket) or GO to N27 (with trailer in-
terface socket)
The right-hand warning lamp in the instru-
ment cluster is inoperative: GO to N32
N19: CHECK THE POWER SUPPLY OF THE HEADLAMP
1 Key in OFF position.
2 Disconnect Right-hand headlamp C147 (con-
ventional headlamp) or C1147 (gas discharge
headlamp).
3 Key in ON position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Switch on the RIGHT-HAND TURN SIGNAL.
5 Measure the voltage between the right-hand
headlamp, connector C147, pin 3 (conven-
tional headlamp), or connector C1147, pin 4
(gas discharge headlamp), circuit 49-LG18
(BU), wiring harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N20
→ No
REPAIR circuit 49-LG18 (BU), between sol-
der point S373 and right-hand headlamp,
using the wiring diagrams. TEST the sys-
tem for normal operation.
N20: CHECK CIRCUIT 31-LE30A (BK)
1 Key in OFF position.
2 Measure the resistance between the right-hand
headlamp, connector C147, pin 6 (conven-
tional headlamp), or connector C1147, pin 7
(gas discharge headlamp), circuit 31-LE30A
(BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the right-
hand headlamp. TEST the system for nor-
mal operation.
→ No
REPAIR circuit 31-LG30A (BK), between
right-hand headlamp and ground G105, us-
ing the wiring diagrams. TEST the system
for normal operation.
N21: CHECK THE POWER SUPPLY OF THE SIDE DIRECTION INDICATOR LAMP
1 Key in OFF position.

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417-01-70 Exterior Lighting 417-01-70

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Side direction indicator lamp RH
side C164.
3 Key in ON position.
4 Switch on the RIGHT-HAND TURN SIGNAL.
5 Measure the voltage between side direction
indicator lamp RH side, connector C164, pin 2,
circuit 49-LG20 (BU/WH), harness side and
ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N22
→ No
REPAIR circuit 49-LG20 (BU/WH), between
solder point S373 and right-hand side re-
peater lamp, using the wiring diagrams.
TEST the system for normal operation.
N22: CHECK CIRCUIT 31-LG20 (BK)
1 Key in OFF position.
2 Measure the resistance between side direction
indicator lamp RH side, connector C164, pin 1,
circuit 31-LG20 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the right-
hand side repeater lamp. TEST the system
for normal operation.
→ No

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417-01-71 Exterior Lighting 417-01-71

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 31-LG20 (BK), between
right-hand side repeater lamp and ground
G105, using the wiring diagrams. TEST the
system for normal operation.
N23: CHECK CIRCUIT 49-LG2 (BU/RD)
1 Key in OFF position.
2 Disconnect Side direction indicator lamp RH
side C164.
3 Disconnect GEM C426.
4 Measure the resistance between side direction
indicator lamp RH side, connector C164, pin 2,
circuit 49-LG20 (BU/WH), harness side and
GEM, connector C426, pin 3, circuit 49-LG2
(BU/RD), harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 49-LG2 (BU/RD), between
GEM and solder point S373, using the wir-
ing diagrams. TEST the system for normal
operation.
N24: CHECK THE POWER SUPPLY OF THE REAR LAMP ASSEMBLY RH SIDE
1 Key in OFF position.
2 Disconnect Right-hand rear lamp assembly
C541 (4-/5-door) or C541b (wagon).
3 Key in ON position.
4 Switch on the RIGHT-HAND TURN SIGNAL.

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417-01-72 Exterior Lighting 417-01-72

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure voltage between right-hand rear lamp
assembly, connector C541, pin 2, circuit 49-
LG19 (BU/RD) (4-/5-door) or connector C541b,
pin 2, circuit 15S-LG12 (GN/YE) (wagon), wir-
ing harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N26
→ No
GO to N25
N25: CHECK CIRCUIT 49-LG19 (BU/RD) OR 15S-LG12 (GN/YE)
1 Key in OFF position.
2 Disconnect GEM C428.
3 Measure resistance between right-hand rear
lamp assembly, connector C541, pin 4, circuit
49-LG19 (BU/RD) (4-/5-door) or connector
C541b, pin 2, circuit 15S-LG12 (GN/YE)
(wagon), wiring harness side and GEM, con-
nector C428, pin 2, circuit 49-LG19 (BU/RD),
wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 49-LG19 (BU/RD) or 15S-
LG12 (GN/YE), between rear lamp assem-
bly and GEM, using the wiring diagrams.
TEST the system for normal operation.
N26: CHECK CIRCUIT 31-LF20 (BK) OR 31-LG12 (BK)
1 Key in OFF position.

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417-01-73 Exterior Lighting 417-01-73

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure resistance between right-hand rear
lamp assembly, connector C541, pin 6, circuit
31-LF20 (BK) (4-/5-door) or connector C541b,
pin 1, circuit 31-LG12 (BK) (wagon), wiring
harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the right-
hand rear lamp assembly. TEST the sys-
tem for normal operation.
→ No
REPAIR circuit 31-LF20 (BK) or 31-LG12
(BK), between right-hand rear lamp assem-
bly and ground G300 (4-/5-door) or G205
(wagon), using the wiring diagrams. TEST
the system for normal operation.
N27: CHECK THE POWER SUPPLY OF THE REAR LAMP ASSEMBLY RH SIDE
1 Key in OFF position.
2 Disconnect Right-hand rear lamp assembly
C2007 (4-/5-door) or C541b (wagon).
3 Key in ON position.
4 Switch on the RIGHT-HAND TURN SIGNAL.
5 Measure voltage between right-hand rear lamp
assembly, connector C2007, pin 2, circuit
(GN/YE) (4-/5-door) or connector C541b, pin 2,
circuit 15S-LG12 (GN/YE) (wagon), wiring
harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N31
→ No
GO to N28

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417-01-74 Exterior Lighting 417-01-74

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
N28: CHECK CIRCUIT 49-LG19 (BU/RD) OR (GN/RD)
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Key in ON position.
4 Switch on the RIGHT-HAND TURN SIGNAL.
5 Measure voltage between trailer switch inter-
face (SI) module, connector C2002, pin 6, cir-
cuit (GN/RD), wiring harness side and ground.

• Does the voltage alternate between 0 volt and

battery voltage?
→ Yes
GO to N30
→ No
GO to N29
N29: CHECK CIRCUIT 49-LG19 (BU/RD) OR (GN/RD)
1 Key in OFF position.
2 Disconnect GEM C428.
3 Measure resistance between trailer switch in-
terface (SI) module, connector C2002, pin 6,
circuit (GN/RD), wiring harness side and GEM,
connector C428, pin 4, circuit 49-LG19
(BU/RD), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No

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417-01-75 Exterior Lighting 417-01-75

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit (GN/RD) or 49-LG19
(BU/RD), between trailer switch interface
(SI) module and GEM, using the wiring dia-
grams. TEST the system for normal opera-
tion.
N30: CHECK CIRCUIT (GN/YE), OR 15S-LG12 (GN/YE)
1 Measure resistance between trailer switch in-
terface (SI) module, connector C2002, pin 10,
circuit (GN/YE), wiring harness side and right-
hand rear lamp assembly, connector C2007,
pin 2, circuit (GN/YE) (4-/5-door) or connector
C541b, pin 2, circuit 15S-LG12 (GN/YE)
(wagon), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK the trailer switch interface (SI)
module, if necessary RENEW it. TEST the
system for normal operation.
→ No
REPAIR circuit (GN/YE) or 15S-LG12
(GN/YE), between trailer switch interface
(SI) module and rear lamp assembly, using
the wiring diagrams. TEST the system for
normal operation.
N31: CHECK CIRCUIT (GN) OR 31-LG12 (BK)
1 Key in OFF position.
2 Measure resistance between right-hand rear
lamp assembly, connector C2007, pin 6, cir-
cuit (GN) (4-/5-door) or connector C541b, pin
1, circuit 31-LG12 (BK) (wagon), wiring har-
ness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the rear
lamp assembly. TEST the system for nor-
mal operation.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR circuit (GN) or 31-LG12 (BK), be-
tween rear lamp assembly and ground
G300 (4-/5-door) or G205 (wagon), using
the wiring diagrams. TEST the system for
normal operation.
N32: CHECK THE POWER SUPPLY OF THE INSTRUMENT CLUSTER
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Key in ON position.
4 Switch on the RIGHT-HAND TURN SIGNAL.
5 Measure the voltage between instrument clus-
ter, connector C449, pin19, circuit 49-LG22
(BU/YE), harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the in-
strument cluster. TEST the system for
normal operation.
→ No
GO to N33
N33: CHECK CIRCUIT 49-LG22 (BU/YE)
1 Key in OFF position.
2 Disconnect GEM C429.
3 Measure the resistance between instrument
cluster, connector C449, pin19, circuit 49-
LG22 (BU/YE), harness side and GEM, con-
nector C429, pin 2,circuit 49-LG22 (BU/YE),
harness side.

• Is the resistance less than 2 ohms?

→ Yes

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417-01-77 Exterior Lighting 417-01-77

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK system using WDS, if necessary
RENEW the generic electronic module
(GEM). TEST the system for normal opera-
tion.
→ No
REPAIR circuit 49-LG22 (BU/YE), between
instrument cluster and GEM, using the wir-
ing diagrams. TEST the system for normal
operation.
PINPOINT TEST O: ONE OR MORE TURN SIGNAL LAMPS ILLUMINATE/FLASH CONTINUALLY
CONDITIONS DETAILS/RESULTS/ACTIONS
O1: READ OUT THE FAULT MEMORY
1 Key in OFF position.
2 Connect the diagnostic tool.
3 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR fault memory. TEST
the system for normal operation.
→ No
Turn signal lamps flashing continuously:
GO to O10
Turn signal lamps permanently lit:
GO to O2
O2: CHECK THE GENERIC ELECTRONIC MODULE (GEM)
1 Key in OFF position.
2 Disconnect GEM C426, C427, C428 and
C429.
3 Key in ON position.
4 Determine the fault condition.
• Is one or more turn signal lamp constantly
on?
→ Yes
GO to O3
→ No
INSTALL a new GEM. TEST the system
for normal operation.
O3: DETERMINE THE FAULT CONDITION
1 Determine the fault condition.
• Are the front and side turn signal lamps on the
left or right lit permanently?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuits connected to sol-
dered connection S371 (left) or S373 (right)
with the aid of the Wiring Diagrams. TEST
the system for normal operation.
→ No
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417-01-78 Exterior Lighting 417-01-78

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
One rear turn signal lamp lit permanently,
vehicle without trailer socket: LOCATE and
RECTIFY the short to battery voltage in the
circuits connected to the rear left or rear
right turn signal lamp with the aid of the Wir-
ing Diagrams. TEST the system for normal
operation.
Both rear turn signal lamps lit permanently,
vehicles with trailer socket: CHECK the
trailer switch interface (SI) module, if neces-
sary RENEW it. TEST the system for nor-
mal operation.
One rear turn signal lamp is permanently lit,
vehicles with trailer socket: GO to O4 (left)
or GO to O6 (right).
The left- or right-hand warning lamp in the
instrument cluster is permanently lit:
GO to O8 (left) or GO to O9 (right).
O4: CHECK TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Key in ON position.
4 Determine the fault condition.
• Is the turn signal lamp permanently switched
on?
→ Yes
LOCATE and REPAIR short to battery volt-
age in circuit (GN/WH), 49-LG12 (BU) or
15S-LG12 (GN/YE), between trailer switch
interface (SI) module and rear lamp as-
sembly, using the wiring diagrams. TEST
the system for normal operation.
→ No
GO to O5
O5: CHECK TRAILER SWITCH INTERFACE (SI) MODULE
1 Measure voltage between trailer switch inter-
face (SI) module, connector C2002, pin 5, cir-
cuit (WH) or 49-LG12 (BU), wiring harness side
and ground.

• Is battery voltage indicated?

→ Yes
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417-01-79 Exterior Lighting 417-01-79

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR short to battery supply in circuit
(WH) or 49-LG12 (BU), connected to trailer
switch interface (SI) module, using the wir-
ing diagrams. TEST the system for normal
operation.
→ No
CHECK the trailer switch interface (SI)
module, if necessary RENEW it. TEST the
system for normal operation.
O6: CHECK TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Key in ON position.
4 Determine the fault condition.
• Is the turn signal lamp permanently switched
on?
→ Yes
REPAIR short to battery supply in circuit
(GN/YE) or 15S-LG12 (GN/YE), connected
to rear lamp assembly, using the wiring dia-
grams. TEST the system for normal opera-
tion.
→ No
GO to O7
O7: CHECK TRAILER SWITCH INTERFACE (SI) MODULE
1 Measure voltage between trailer switch inter-
face (SI) module, connector C2002, pin 6, cir-
cuit (GN/RD) or 49-LG19 (BU/RD), wiring har-
ness side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR short to battery supply in circuit
(GN/RD) or 49-LG19 (BU/RD), connected
to trailer switch interface (SI) module, using
the wiring diagrams. TEST the system for
normal operation.
→ No
CHECK the trailer switch interface (SI)
module, if necessary RENEW it. TEST the
system for normal operation.

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417-01-80 Exterior Lighting 417-01-80

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
O8: CHECK CIRCUIT 49-LG15 (BU/BK)
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Measure the voltage between GEM, connector
C429, pin 3, circuit 49-LG15(BU/BK), harness
side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR short to battery supply in circuit 49-
LG15 (BU/BK), connected to the instrument
cluster, using the wiring diagrams. TEST
the system for normal operation.
→ No
CHECK and if necessary RENEW the in-
strument cluster. TEST the system for
normal operation.
O9: CHECK CIRCUIT 49-LG22 (BU/YE)
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Measure the voltage between GEM, connector
C429, pin 2, circuit 49-LG22(BU/YE), harness
side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR short to battery voltage in circuit
49-LG22 (BU/YE), connected to the instru-
ment cluster, using the wiring diagrams.
TEST the system for normal operation.
→ No

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417-01-81 Exterior Lighting 417-01-81

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK and if necessary RENEW the in-
strument cluster. TEST the system for
normal operation.
O10: DETERMINE THE FAULT CONDITION
1 Determine the fault condition.
• Do all turn signal lamps flash continuously?
→ Yes
GO to O11
→ No
The turn signal lamps on the left-hand side
flash continuously: GO to O13
The turn signal lamps on the right-hand side
flash continuously: GO to O15
The front and side left or right turn signal
lamps, or the rear left or right turn signal
lamps flash continually. RENEW the generic
electronic module (GEM) TEST the system
for normal operation.
Left- or right-hand warning lamp in the in-
strument cluster flashes continuously:
GO to O17
O11: CHECK CIRCUIT 91S-LG8 (BK/OG)
1 Key in OFF position.
2 Disconnect GEM C429.
3 Measure the resistance between GEM, con-
nector C429, pin 23, circuit 91S-LG8 (BK/OG),
harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
INSTALL a new GEM. TEST the system
for normal operation.
→ No
GO to O12
O12: CHECK THE HAZARD WARNING LAMP SWITCH
1 Key in OFF position.
2 Disconnect Hazard warning lamp switch C438.

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417-01-82 Exterior Lighting 417-01-82

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between GEM, con-
nector C429, pin 23, circuit 91S-LG8 (BK/OG),
harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
RENEW the hazard warning lamp switch.
TEST the system for normal operation.
→ No
REPAIR short to ground in circuit 91S-LG8
(BK/OG), connected to the instrument clus-
ter, using the wiring diagrams. TEST the
system for normal operation.
O13: CHECK CIRCUIT 91S-LG27B (BK/GN)
1 Key in OFF position.
2 Disconnect GEM C429.
3 Measure the resistance between GEM, con-
nector C429, pin 17, circuit 91S-LG27B
(BK/GN), harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
INSTALL a new GEM. TEST the system
for normal operation.
→ No
GO to O14
O14: CHECK THE TURN SIGNAL SWITCH
1 Key in OFF position.
2 Disconnect Turn signal switch C529.

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417-01-83 Exterior Lighting 417-01-83

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between GEM, con-
nector C429, pin 17, circuit 91S-LG27B
(BK/GN), harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
RENEW the turn signal switch. TEST the
system for normal operation.
→ No
REPAIR short to ground in circuit 91S-
LG27B (BK/GN), using the wiring diagrams.
TEST the system for normal operation.
O15: CHECK CIRCUIT 91S-LG27A (BK/GN)
1 Key in OFF position.
2 Disconnect GEM C429.
3 Measure the resistance between GEM, con-
nector C429, pin 19, circuit 91S-LG27A
(BK/GN), harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
INSTALL a new GEM. TEST the system
for normal operation.
→ No
GO to O16
O16: CHECK THE TURN SIGNAL SWITCH
1 Key in OFF position.
2 Disconnect Turn signal switch C529.

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417-01-84 Exterior Lighting 417-01-84

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between GEM, con-
nector C429, pin 19, circuit 91S-LG27A
(BK/GN), harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
RENEW the turn signal switch. TEST the
system for normal operation.
→ No
REPAIR short to ground in circuit 91S-
LG27A (BK/GN), using the wiring diagrams.
TEST the system for normal operation.
O17: CHECK THE INSTRUMENT CLUSTER
1 Key in OFF position.
2 Disconnect GEM C429.
3 Check warning lamp in instrument cluster.
• Does the left-or right-hand warning lamp flash
continually?
→ Yes
INSTALL a new instrument cluster. TEST
the system for normal operation.
→ No
INSTALL a new GEM. TEST the system
for normal operation.

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417-01-85 Exterior Lighting 417-01-85

DIAGNOSIS AND TESTING

Parking, Rear and License Lamps

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Inspection and Verification
Special Tool(s)
1. Verify the customer concern by operating the
Digital multimeter system.
105-R0051 or a comparable 2. Visually inspect for obvious signs of
device mechanical or electrical damage.

Visual Check
Electrical
Terminal probe kit • Fuse(s).
29-011 A • Bulb(s).
• Wiring harness.
• Electrical connector(s).
• Switch(es).
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Parking lamps, rear lamps and • Fuse(s). • GO to Pinpoint Test P
license lamps are inoperative • Circuit(s).
• Headlamp switch.
• Battery junction box (BJB)
• One or more parking lights, rear • Fuse(s). • GO to Pinpoint Test Q
lamps or license plate lamps not • Circuit(s).
operating • Headlamp switch.
• Ignition switch
• Headlamp.
• Tail Lamp Assembly
• License plate lamp.
• Instrument cluster.
• Central Junction Box (CJB).
• Parking lamps, rear lamps • Circuit(s). • GO to Pinpoint Test R
and/or license plate lamp lit • Headlamp switch.
continuously • Instrument cluster.
• Trailer interface (TI) module
• Generic electronic module
(GEM)
• Central Junction Box (CJB)

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417-01-86 Exterior Lighting 417-01-86

DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests
PINPOINT TEST P: PARKING LAMPS, REAR LAMPS AND LICENSE LAMPS ARE INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
P1: TEST PARKING LAMPS WITH PARKING LIGHTS SWITCHED ON, AND WITH DIPPED BEAM
SWITCHED ON
1 Switch on side light.
2 Test the parking lamps.
• Do the parking lamps, rear lamps and license
plate lamps illuminate?
→ Yes
Parking lamps inoperative when dipped
beam switched on: RENEW the light
switch. TEST the system for normal opera-
tion.
→ No
All lamps inoperative: GO to P2
Parking lamps inoperative, license plate
lamps OK: GO to Q1
P2: CHECK FUSE F21 (BJB)
1 Key in OFF position.
2 CHECK Fuse F21 (BJB).
3 Check fuse F21 (15 A).
• Is the fuse OK?
→ Yes
GO to P3
→ No
RENEW fuse F21 (15 A) and CHECK the
operation of the system. If the fuse blows
again, LOCATE and REPAIR the short us-
ing the wiring diagrams. TEST the system
for normal operation.
P3: CHECK THE VOLTAGE AT FUSE F21 (BJB)
1 Connect Fuse F21 (BJB).
2 Key in ON position.
3 Measure the voltage between fuse F21 (BJB)
and ground.
• Is battery voltage indicated?
→ Yes
GO to P4
→ No
TEST the battery junction box (BJB),
RENEW it if necessary. TEST the system
for normal operation.
P4: CHECK THE VOLTAGE SUPPLY AT THE LIGHT SWITCH
1 Key in OFF position.
2 Disconnect Headlamp switch C478.

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417-01-87 Exterior Lighting 417-01-87

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the light switch,
connector C478, pin 11, circuit 30-LE21 (RD),
wiring harness side, and ground.

• Is battery voltage indicated

→ Yes
INSTALL a new headlamp switch. TEST the
system for normal operation.
→ No
REPAIR break in circuit 30-LE21 (RD), be-
tween fuse F21 and light switch using the
wiring diagrams. TEST the system for
normal operation.
PINPOINT TEST Q: ONE OR MORE PARKING LIGHTS, REAR LAMPS OR LICENSE PLATE
LAMPS NOT WORKING
CONDITIONS DETAILS/RESULTS/ACTIONS
Q1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
1 Switch on the PARKING LIGHTS and the SIDE
LIGHTS one after the other.
2 Test the parking lamps.
• Are all parking lamps inoperative in both light
switch positions (license plate lamps OK in
SIDELIGHT position)?
→ Yes
GO to Q23
→ No
Individual parking lamp(s) is/are inoperative:
GO to Q2
Parking lamps inoperative when PARKING
LIGHTS switched on, OK when
SIDELIGHTS switched on:.: GO to Q19
(without daytime running lamps) or
GO to Q22 (with daytime running lamps)
Q2: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
1 Switch on side lights.
2 Test the parking lamps.
• Is/are the parking lamp(s) on the right-hand
side inoperative?
→ Yes
All right-hand parking lamps: GO to Q3

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417-01-88 Exterior Lighting 417-01-88

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Front right-hand parking lamps: GO to Q5
Rear right-hand parking lamps: GO to Q7
The license plate lamp(s) is/are inoperative:
GO to Q11
→ No
All left-hand parking lamps: GO to Q4
Front left-hand parking lamp: GO to Q6
Rear left-hand parking lamps: GO to Q9
The license plate lamp(s) is/are inoperative:
GO to Q11
The LIGHTS ON display is inoperative:
GO to Q18
Q3: CHECK FUSE F63 (CJB)
1 Key in OFF position.
2 CHECK Fuse F63 (CJB).
3 Check fuse F63 (7.5 A).
• Is the fuse OK?
→ Yes
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
→ No
INSTALL a new fuse F63 (7.5 A). If the
fuse blows again, LOCATE and REPAIR the
short using the wiring diagrams. TEST the
system for normal operation.
Q4: CHECK FUSE F64 (CJB)
1 Key in OFF position.
2 CHECK Fuse F64 (CJB).
3 Check fuse F64 (7.5 A).
• Is the fuse OK?
→ Yes
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
→ No
INSTALL a new fuse F64 (7.5 A). If the
fuse blows again, LOCATE and REPAIR the
short using the wiring diagrams. TEST the
system for normal operation.
Q5: CHECK VOLTAGE SUPPLY AT RIGHT-HAND HEADLAMP
1 Disconnect Right-hand headlamp C147 (con-
ventional headlamp) or C1147 (gas discharge
headlamp).
2 Switch on the PARKING LAMPS.

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417-01-89 Exterior Lighting 417-01-89

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the right-hand
headlamp, connector C147, pin 4 (conven-
tional headlamp), or connector C1147, pin 8
(gas discharge headlamp), circuit 29S-LF16
(OG/GN), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR the ground connection of the head-
lamp with the aid of the Wiring Diagrams, if
necessary RENEW the headlamp. TEST
the system for normal operation.
→ No
REPAIR the break in circuit between fuse
F63 (CJB) and the right-hand headlamp us-
ing the wiring diagrams, RENEW the central
junction box (CJB) if necessary. TEST the
system for normal operation.
Q6: CHECK VOLTAGE SUPPLY AT LEFT-HAND HEADLAMP
1 Disconnect Left-hand headlamp C146 (con-
ventional headlamp) or C1146 (gas discharge
headlamp).
2 Switch on the PARKING LAMPS.

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417-01-90 Exterior Lighting 417-01-90

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the left-hand
headlamp, connector C146, pin 4 (conven-
tional headlamp), or connector C1146, pin 8
(gas discharge headlamp), circuit 29S-LF7
(OG/BU), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR the ground connection of the head-
lamp with the aid of the Wiring Diagrams, if
necessary RENEW the headlamp. TEST
the system for normal operation.
→ No
REPAIR the break in circuit between fuse
F64 (CJB) and the left-hand headlamp us-
ing the wiring diagrams, RENEW the central
junction box (CJB) if necessary. TEST the
system for normal operation.
Q7: CHECK THE VOLTAGE SUPPLY AT THE RIGHT-HAND REAR LAMP ASSEMBLY
1 Disconnect Right-hand rear lamp assembly.
- C541 (4-/5-door, without trailer socket)
- C2007 (4-/5-door, with trailer socket)
- C541d Wagon
2 Switch on the PARKING LAMPS.
3 Measure the voltage between the right-hand
rear lamp assembly. …
- 4/5 doors: connector C541, pin 1, circuit 29S-
LF20 (OG) (without trailer socket) or
connector C2007, pin 1, circuit (GY/RD) (with
trailer socket), wiring harness side and
ground.
- Wagon: connector C541d, pin 2, circuit 29S-
LF11 (OG/WH), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to Q8
→ No

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417-01-91 Exterior Lighting 417-01-91

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
The LIGHTS ON display is OK: REPAIR
break in circuit (GY/RD), 29S-LF20 (OG) or
29S-LF11 (OG/WH), between CJB and
right-hand rear lamp assembly, using the
wiring diagrams. TEST the system for
normal operation.
The LIGHTS ON display is inoperative:
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
Q8: CHECK GROUND CONNECTION OF RIGHT-HAND REAR LAMP ASSEMBLY
1 Measure the resistance between the right-hand
rear lamp assembly, …
- 4/5 doors: connector C541, pin 6, circuit 31-
LF20 (BK) (without trailer socket) or
connector C2007, pin 6, circuit (GN) (with
trailer socket), wiring harness side and
ground.
- Wagon: Connector C541d, pin 1, circuit 31-
LF11 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the rear
lamp assembly. TEST the system for nor-
mal operation.
→ No
REPAIR break in circuit (GN), 31-LF20 (BK)
or 31-LF11 (BK), between rear lamp as-
sembly and ground G300 or G205 (wagon),
using the wiring diagrams. TEST the sys-
tem for normal operation.
Q9: CHECK THE VOLTAGE SUPPLY AT THE LEFT-HAND REAR LAMP ASSEMBLY
1 Disconnect Left-hand rear lamp assembly.
- C540 (4-/5-door, without trailer socket)
- C2005 (4-/5-door, with trailer socket)
- C540d Wagon
2 Switch on the PARKING LAMPS.

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417-01-92 Exterior Lighting 417-01-92

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the left-hand
rear lamp assembly, …
- 4/5 doors: connector C540, pin 1, circuit 29S-
LF11 (OG/WH) (without trailer socket) or
connector C2005, pin 1, circuit (GY/BK) (with
trailer socket), wiring harness side and
ground.
- Wagon: connector C540d, pin 2, circuit 29S-
LF11 (OG/WH), wiring harness side and
ground.

• Is battery voltage indicated

→ Yes
GO to Q10
→ No
REPAIR the break in circuit between fuse
F64 (CJB) and the left-hand rear lamp as-
sembly using the wiring diagrams, RENEW
the central junction box (CJB) if necessary.
TEST the system for normal operation.
Q10: CHECK GROUND CONNECTION OF LEFT-HAND REAR LAMP ASSEMBLY
1 Measure the resistance between the left-hand
rear lamp assembly, …
- 4/5 doors: connector C540, pin 6, circuit 31-
LF11 (BK) (without trailer socket) or
connector C2005, pin 6, circuit (BN) (with
trailer socket), wiring harness side and
ground.
- Wagon: Connector C540d, pin 1, circuit 31-
LF11 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the rear
lamp assembly. TEST the system for nor-
mal operation.
→ No
REPAIR break in circuit (BN) or 31-LF11
(BK), between rear lamp assembly and
ground G300, using the wiring diagrams.
TEST the system for normal operation.
Q11: CHECK LICENSE PLATE LAMPS
1 Switch on side lights.
2 Check the license plate lamps.

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417-01-93 Exterior Lighting 417-01-93

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are both license plate lamps inoperative?

→ Yes
GO to Q12
→ No
Left-hand license plate lamp inoperative:
GO to Q16
Right-hand license plate lamp inoperative:
GO to Q17
Q12: CHECK FUSE F97 (CJB)
1 Key in OFF position.
2 CHECK Fuse F97 (CJB).
3 Check fuse F97 (7.5 A).
• Is the fuse OK?
→ Yes
GO to Q13
→ No
INSTALL a new fuse F97 (7.5 A). If the
fuse blows again, LOCATE and REPAIR the
short to ground using the wiring diagrams.
TEST the system for normal operation.
Q13: CHECK POWER SUPPLY TO FUSE F97 (CJB)
1 Connect Fuse F97 (CJB).
2 Switch on the PARKING LAMPS.
3 Test voltage between fuse F97 (7.5 A) and
ground.
• Is battery voltage indicated?
→ Yes
GO to Q14
→ No
GO to Q15
Q14: CHECK THE VOLTAGE SUPPLY AT THE RIGHT-HAND LICENSE PLATE LAMP
1 Disconnect License plate lamp RH side C735a.
2 Switch on side light.
3 Measure the voltage between right-hand li-
cense lamp, connector C735a, circuit 29S-
LF21 (OG/BK), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes

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417-01-94 Exterior Lighting 417-01-94

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
RECTIFY the break in circuit 31-LF21 (BK)
between the left-hand license plate lamp
and ground connection G300 with the aid of
the Wiring Diagrams. TEST the system for
normal operation.
→ No
REPAIR the break in circuit between fuse
F97 (CJB) and the right-hand license plate
lamp using the wiring diagrams, RENEW
the central junction box if necessary.
TEST the system for normal operation.
Q15: CHECK THE CIRCUIT BETWEEN THE LIGHT SWITCH AND FUSE F97 (CJB)
1 Disconnect Headlamp switch C478.
2 Measure resistance between fuse F97 (CJB)
and light switch, connector C478, pin 16, cir-
cuit 30S-LF12 (RD/GN), wiring harness side.

• Is the resistance less than 2 ohms

→ Yes
CHECK and if necessary RENEW the light
switch. TEST the system for normal opera-
tion.
→ No
REPAIR the break in circuit between light
switch and fuse F97 (CJB) using the wiring
diagrams, RENEW the central junction box
(CJB) if necessary. TEST the system for
normal operation.
Q16: CHECK VOLTAGE SUPPLY TO LEFT-HAND LICENSE PLATE LAMP
1 Disconnect License plate lamp LH side C736a.
2 Switch on side light.

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417-01-95 Exterior Lighting 417-01-95

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between left-hand license
plate lamp, connector C736a, circuit 29S-LF22
(OG/BK), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the left-
hand license plate lamp. TEST the system
for normal operation.
→ No
REPAIR break in circuit 29S-LF22 (OG/BK),
between left-hand license plate lamp and
right-hand license plate lamp using the wir-
ing diagrams. TEST the system for normal
operation.
Q17: CHECK GROUND CONNECTION OF RIGHT-HAND LICENSE PLATE LAMP
1 Disconnect License plate lamp RH side C735b.
2 Measure the resistance between right-hand
license plate lamp, connector C735b, circuit
31-LF22 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the right-
hand license plate lamp. TEST the system
for normal operation.
→ No
REPAIR break in circuit 31-LF22 (BK), be-
tween left-hand license plate lamp and
right-hand license plate lamp using the wir-
ing diagrams. TEST the system for normal
operation.

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417-01-96 Exterior Lighting 417-01-96

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Q18: CHECK CIRCUIT 29S-GM12 (OG/BK) BETWEEN FUSE F63 (CJB) AND INSTRUMENT
CLUSTER
1 Disconnect Instrument cluster C449.
2 Measure the voltage between instrument clus-
ter, connector C449, pin 27, circuit 29S-GM12
(OG/BK), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the in-
strument cluster. TEST the system for
normal operation.
→ No
REPAIR break in circuit 29S-GM12
(OG/BK), between fuse F63 (CJB) and in-
strument cluster using the wiring diagrams.
TEST the system for normal operation.
Q19: CHECK FUSE F28 (BJB)
1 Key in OFF position.
2 CHECK Fuse F28 (BJB).
3 Check fuse F28 (20 A).
• Is the fuse OK?
→ Yes
GO to Q20
→ No
RENEW fuse F28 (20 A) and CHECK the
operation of the system. If the fuse blows
again, LOCATE and REPAIR the short to
ground using the wiring diagrams. TEST
the system for normal operation.
Q20: CHECK THE VOLTAGE AT FUSE F28 (BJB)
1 Connect Fuse F28 (BJB).
2 Key in ON position.
3 Measure the voltage between fuse F28 (BJB)
and ground.
• Is battery voltage indicated?
→ Yes
GO to Q21
→ No

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417-01-97 Exterior Lighting 417-01-97

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.
Q21: TEST THE VOLTAGE AT THE IGNITION SWITCH
1 Key in OFF position.
2 Disconnect Ignition switch C400.
3 Key in ON position.
4 Measure the voltage between the ignition
switch, connector C400, pin 4, circuit 30-BB9
(RD), wiring harness side, and ground.

• Is battery voltage indicated?

→ Yes
CHECK the ignition switch according to the
component checks in the wiring diagrams
and RENEW it if necessary. TEST the sys-
tem for normal operation. If the concern
persists: GO to Q22
→ No
REPAIR break in circuit 30-BB9 (RD), be-
tween fuse F28 and ignition switch using
the wiring diagrams. TEST the system for
normal operation.
Q22: TEST VOLTAGE ON LIGHT SWITCH
1 Key in OFF position.
2 Connect Ignition switch C400 (vehicles without
daytime running lights).
3 Disconnect Headlamp switch C478.
4 Measure the voltage between the light switch,
connector C478, pin 12, circuit 30S-LF14
(RD/OG), wiring harness side and ground.

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417-01-98 Exterior Lighting 417-01-98

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the light
switch. TEST the system for normal opera-
tion.
→ No
REPAIR break in circuit 30S-LF14 (RD/OG)
using the wiring diagrams. TEST the sys-
tem for normal operation.
Q23: CHECK THE CIRCUIT BETWEEN THE LIGHT SWITCH AND FUSE F63 (CJB)
1 Disconnect Headlamp switch C478.
2 Measure resistance between fuse F63 (CJB)
and light switch, connector C478, pin 13, 30S-
LF2 (RD/BU), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the light
switch. TEST the system for normal opera-
tion.
→ No
REPAIR the break in circuit between light
switch and fuses F63, F64 (CJB) using the
wiring diagrams, RENEW the central junc-
tion box (CJB) if necessary. TEST the sys-
tem for normal operation.
PINPOINT TEST R: PARKING LAMPS, REAR LAMPS AND/OR LICENSE PLATE LAMP LIT
CONTINUOUSLY
CONDITIONS DETAILS/RESULTS/ACTIONS
R1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
1 Key in OFF position.
2 Disconnect Headlamp switch C478.
3 Key in ON position.
4 Test the parking lamps
• Are the parking lamps and the license plate
lamps lit continuously?
→ Yes
CHECK and if necessary RENEW the light
switch. TEST the system for normal opera-
tion.
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417-01-99 Exterior Lighting 417-01-99

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
The parking lamps are on continuously:
GO to R2
The license plate lamps stay on continu-
ously: GO to R6
R2: CHECK THE VOLTAGE SUPPLY TO FUSES F63, F64 (CJB) FOR A SHORT TO BATTERY
VOLTAGE
1 Key in OFF position.
2 Disconnect Fuse F63 (CJB).
3 Disconnect Fuse F64 (CJB).
4 Key in ON position.
5 Test the parking lamps
• Are the parking lamps lit continuously on one
side?
→ Yes
Right-hand parking lamps lit continuously:
GO to R3
Left-hand parking lamps lit continuously:
GO to R4
→ No
LOCATE and REPAIR the short to battery
voltage in circuit, between light switch and
fuses F63, F64 (CJB) using the wiring dia-
grams, RENEW the central junction box
(CJB) if necessary. TEST the system for
normal operation.
R3: CHECK THE INSTRUMENT CLUSTER
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Key in ON position.
4 Test the right-hand parking lamps.
• Are the right-hand parking lamps lit continu-
ously?
→ Yes
GO to R4
→ No
CHECK and if necessary RENEW the in-
strument cluster. TEST the system for
normal operation.
R4: DETERMINE VEHICLE EQUIPMENT LEVEL
1 Determine vehicle equipment level.
• Is the vehicle equipped with a trailer socket?
→ Yes
GO to R5
→ No

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417-01-100 Exterior Lighting 417-01-100

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY short to battery
voltage in the circuits which are connected
to output of fuse F64 (left side lit all time) or
output of fuse F63 (right side lit all time) us-
ing the wiring diagrams, RENEW the central
junction box (CJB) if necessary. TEST the
system for normal operation.
R5: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Test the parking lamps
• Are the parking lamps lit continuously on one
side?
→ Yes
LOCATE and RECTIFY short to battery
voltage in the circuits which are connected
to output of fuse F64 (left side lit all time) or
output of fuse F63 (right side lit all time) us-
ing the wiring diagrams, RENEW the central
junction box (CJB) if necessary. TEST the
system for normal operation.
→ No
RENEW trailer interface (TI) module. TEST
the system for normal operation.
R6: CHECK THE VOLTAGE SUPPLY TO FUSE F97 (CJB) FOR A SHORT TO BATTERY
VOLTAGE
1 Key in OFF position.
2 Disconnect Fuse F97 (CJB).
3 Key in ON position.
4 Check the license plate lamps.
• Does the license plate lamps stay on continu-
ously?
→ Yes
GO to R7
→ No
LOCATE and REPAIR the short to battery
voltage in circuit, between light switch and
fuse F97, (CJB) using the wiring diagrams,
RENEW the central junction box (CJB) if
necessary. TEST the system for normal
operation.
R7: CHECK GEM
1 Key in OFF position.
2 Disconnect Generic electronic module (GEM)
C429.
3 Key in ON position.
4 Check the license plate lamps.

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417-01-101 Exterior Lighting 417-01-101

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the license plate lamps stay on continu-

ously?
→ Yes
GO to R8
→ No
CHECK and if necessary RENEW the ge-
neric electronic module (GEM). TEST the
system for normal operation.
R8: CHECK CIRCUIT 29S-GG17 (OG)
1 Key in OFF position.
2 Disconnect Central Junction Box (CJB) C502.
3 Key in ON position.
4 Check the license plate lamps.
• Do the license plate lamps stay on continu-
ously?
→ Yes
GO to R9
→ No
LOCATE and RECTIFY the short to battery
voltage in circuit 29S-GG17 (OG), between
the CJB and the GEM using the Wiring Dia-
grams. TEST the system for normal opera-
tion.
R9: CHECK CIRCUITS 29S-LF21 (OG/BK), 29S-LF22 (OG/BK) TO THE LICENSE PLATE LAMPS
1 Key in OFF position.
2 Disconnect Central Junction Box (CJB) C508.
3 Key in ON position.
4 Check the license plate lamps.
• Do the license plate lamps stay on continu-
ously?
→ Yes
LOCATE and REPAIR short to battery volt-
age in circuit 29S-LF21 (OG/BK) or 29S-
LF22 (OG/BK), between CJB and license
plate lamps using the wiring diagrams.
TEST the system for normal operation.
→ No
CHECK and if necessary RENEW the cen-
tral junction box (CJB). TEST the system
for normal operation.

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417-01-102 Exterior Lighting 417-01-102

DIAGNOSIS AND TESTING

Fog Lamps

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Diagnosis and Testing
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electrical damage.
device
Visual Check
Electrical
• Fuse(s).
Terminal probe kit • Bulb(s).
29-011 A • Fog lamps.
• Electrical connector(s).
• Switch(es).
• Wiring harness.
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 cause is not visually evident, verify the
symptom and referto the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• The fog lamps are inoperative • Fuse(s). • GO to Pinpoint Test S
• Circuit(s).
• Light switch
• Rear fog lamp shut-off relay
• Individual fog lamp inoperative • Circuit(s). • GO to Pinpoint Test T
• Front fog lamp
• Rear fog lamp
• The fog lamps are on continu- • Circuit(s). • GO to Pinpoint Test U
ously • Light switch
• Rear fog lamp shut-off relay

Pinpoint Tests
PINPOINT TEST S: THE FOG LAMPS ARE INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
S1: CHECK THE CAUSE OF THE FAULT
1 Key in ON position.
2 Switch on the FRONT and REAR FOG
LAMPS.
3 Check the fog lamps.
• Are all of the fog lamps not working?
→ Yes

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417-01-103 Exterior Lighting 417-01-103

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to S2
→ No
Front fog lamps inoperative: GO to S5
Rear fog lamps inoperative: GO to S7
S2: CHECK FUSE F62
1 Key in OFF position.
2 CHECK Fuse F62 (CJB).
3 Check the fuse F62 (15 A).
• Is the fuse OK?
→ Yes
GO to S3
→ No
INSTALL a new fuse F62 (15 A). Check
the operation of the system. If the fuse
blows again, LOCATEand REPAIR the short
circuit to ground by using the wiring dia-
grams. CHECK the operation of the sys-
tem.
S3: TEST VOLTAGE AT FUSE F62
1 Connect Fuse F62 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F62 (CJB)
and ground.
• Is battery voltage indicated?
→ Yes
GO to S4
→ No
LOCATE and RECTIFY the break in the
voltage supply to fuse F62 with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
S4: CHECK CIRCUIT 15-LD10 (GN/OG)
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Measure the resistance between the light
switch, connector C478, pin 7, circuit 15-LD10
(GN/OG), wiring harness side and fuse F62
(CJB).

• Is the resistance less than 2 ohms?

→ Yes
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417-01-104 Exterior Lighting 417-01-104

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Renew the light switch. CHECK the opera-
tion of the system.
→ No
REPAIR circuit 15-LD10 (GN/OG) between
fuse F62 and the light switch with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
S5: CHECK THE LIGHT SWITCH
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Using a fused test cable (15 A) at the light
switch, bridge between connector C478, pin 7,
circuit 15-LD10 (GN/OG) and pin 3, circuit 15S-
LD10 (GN/OG), wiring harness side.

4 Key in ON position.
5 Check the front fog lamps.
• Are the front fog lamps illuminated?
→ Yes
Renew the light switch. CHECK the opera-
tion of the system.
→ No
GO to S6
S6: CHECK CIRCUITS 15S-LD10 (GN/OG) AND 15S-LD9 (GN/BK)
1 Key in OFF position.
2 Connect Light switch (C478).
3 Disconnect Front fog lamp left-hand side C207.
4 Key in ON position.
5 Switch on the front fog lamps.
6 Measure the voltage between front fog lamp
left-hand side, connector C207, pin 1, circuit
15S-LD11 (GN/WH), harness side and ground.

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417-01-105 Exterior Lighting 417-01-105

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage indicated?

→ Yes
REPAIR the circuit between soldered con-
nection S734 and ground connection G104
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
→ No
REPAIR circuit 15S-LD10 (GN/OG) or 15S-
LD9 (GN/BK) with the aid of the wiring dia-
grams. CHECK the operation of the sys-
tem.
S7: CHECK THE LIGHT SWITCH.
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Using a fused test cable (15 A) at the light
switch, bridge between connector C478, pin 7,
circuit 15-LD10 (GN/OG) and pin 2, circuit 15S-
LD16 (GN/RD), wiring harness side.

4 Key in ON position.
5 If the rear fog lamps are still inoperative, re-
move the bridging cable (estate versions with-
out a trailer socket only).
6 Check the rear fog lamps.
• Are the rear fog lamps illuminated?
→ Yes
Renew the light switch. CHECK the opera-
tion of the system.
→ No
4/5-door versions without a trailer socket:
GO to S8
Estate versions without a trailer socket:
REPAIR circuit 15S-LD16 (GN/RD) or 15S-
LD6 (GN/YE) between the light switch and
the rear lamp cluster with the aid of the Wir-
ing Diagrams. CHECK the operation of the
system.
Vehicles with a trailer socket: GO to S9
S8: CHECK CIRCUITS 15S-LD16 (GN/RD) AND 15S-LD6 (GN/YE)
1 Key in OFF position.
2 Disconnect Rear fog lamp C540.
3 Key in ON position.

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417-01-106 Exterior Lighting 417-01-106

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the left-hand
rear fog lamp, connector C540, pin 7, circuit
15S-LD6 (GN/YE), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
REPAIR circuit 31-DA7 (BK) between sol-
dered connection S211 and ground con-
nection G300 with the aid of the wiring dia-
grams. CHECK the operation of the sys-
tem.
→ No
REPAIR circuit 15S-LD16 (GN/RD) or 15S-
LD6 (GN/YE) between the light switch and
the left-hand rear fog lamp with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
S9: CHECK CIRCUITS 15S-LD16 (GN/RD) AND 15S-LD6 (GN/YE)
1 Key in OFF position.
2 Disconnect Rear fog lamp shut-off relay
C2008.
3 Key in ON position.
4 Measure the voltage between the rear fog
lamp shut-off relay, connector C2008, circuit
(RD/WH), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to S10
→ No

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417-01-107 Exterior Lighting 417-01-107

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 15S-LD16 (GN/RD) or 15S-
LD6 (GN/YE) between the light switch and
the rear fog lamp shut-off relay with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
S10: CHECK CIRCUIT (BN)
1 Key in OFF position.
2 Measure the resistance between the rear fog
lamp shut-off relay, connector C2008, circuit
(BN), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to S11
→ No
REPAIR circuit (BN) or 31-DA7 (BK) be-
tween the rear fog lamp shut-off relay and
ground connection G300 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
S11: CHECK CIRCUIT (RD/YE)
NOTE: Check that no adapters or consumers are connected to the trailer socket.
1 Key in OFF position.
2 Measure the resistance between the rear fog
lamp shut-off relay, connector C2008, circuit
(RD/YE), wiring harness side and ground.

• Is the resistance greater than 10 kOhms?

→ Yes
CHECK and if necessary RENEW the rear
fog lamp shut-off relay. CHECK the opera-
tion of the system.
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417-01-108 Exterior Lighting 417-01-108

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
LOCATE and RECTIFY the short to ground
in circuit (RD/YE) between the rear fog
lamp shut-off relay and the trailer socket
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
PINPOINT TEST T: INDIVIDUAL FOG LAMP INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
T1: DETERMINE THE INOPERATIVE LAMP(S)
1 Key in ON position.
2 Switch on the FRONT and REAR FOG
LAMPS.
3 Check the fog lamps.
• Is a single fog lamp inoperative?
→ Yes
Left-hand side: GO to T2
Right-hand side: GO to T4
→ No
Right-hand rear fog lamp: GO to T6
Left-hand rear fog lamp, estate and 4/5-door
versions with a trailer socket: GO to T8
Left-hand rear fog lamp, 4/5-door versions
without a trailer socket: GO to T9
T2: CHECK CIRCUIT 15S-LD11 (GN/WH)
1 Key in OFF position.
2 Disconnect Front fog lamp left-hand side C207.
3 Key in ON position.
4 Switch on the front fog lamps.
5 Measure the voltage between front fog lamp
left-hand side, connector C207, pin 1, circuit
15S-LD11 (GN/WH), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to T3
→ No

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417-01-109 Exterior Lighting 417-01-109

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the circuit 15S-LD11 (GN/WH) be-
tween soldered connection S733 and the
front fog lamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
T3: CHECK CIRCUIT 31-LD11 (BK)
1 Key in OFF position.
2 Measure the resistance between front fog lamp
left-hand side, connector C207, pin 2, circuit
31-LD11 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand front fog lamp. CHECK the operation
of the system.
→ No
REPAIR the circuit 31-LD11 (BK) between
the front fog lamp and soldered connection
S734 with the aid of the Wiring Diagrams.
Check the operation of the system.
T4: CHECK CIRCUIT 15S-LD17 (GN/WH)
1 Key in OFF position.
2 Disconnect Front fog lamp right-hand side
C208.
3 Key in ON position.
4 Switch on the front fog lamps.
5 Measure the voltage between front fog lamp
right-hand side, connector C208, pin 1, circuit
15S-LD17 (GN/WH), harness side and ground.

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417-01-110 Exterior Lighting 417-01-110

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage indicated?

→ Yes
GO to T5
→ No
REPAIR the circuit 15S-LD17 (GN/WH) be-
tween soldered connection S733 and the
front fog lamp with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
T5: CHECK CIRCUIT 31-LD17 (BK)
1 Key in OFF position.
2 Measure the resistance between the right-hand
front fog lamp, connector C208, pin 2, circuit
31-LD17 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the right-
hand front fog lamp. CHECK the operation
of the system.
→ No
REPAIR the circuit 31-LD17 (BK) between
the front fog lamp and soldered connection
S734 with the aid of the Wiring Diagrams.
CHECK the operation of the system.
T6: CHECK CIRCUIT 15S-LD12 (GN/YE) OR 15S-LD6 (GN/YE)
1 Key in OFF position.
2 Disconnect Right-hand rear lamp cluster.
- C541 (4/5-door versions without a trailer
socket)
- C2007 (4/5-door versions with a trailer
socket)
- C541 estate
3 Key in ON position.
4 Switch on the REAR FOG LAMPS.

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417-01-111 Exterior Lighting 417-01-111

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the right-hand
rear lamp cluster, …
- 4/5-door versions: connector C541, pin 7,
circuit 15S-LD12 (GN/YE) (without a trailer
socket) or connector C2007, pin 7, circuit
(VT/YE) (with a trailer socket), wiring harness
side and ground.
- Estate: connector C541d, pin 3, circuit 15S-
LD6 (GN/YE), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to T7
→ No
REPAIR circuit (VT/YE), 15S-LD6 (GN/YE)
or 15S-LD12 (GN/YE) with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
T7: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND REAR LAMP CLUSTER
1 Key in OFF position.
2 Measure the resistance between the right-hand
rear lamp cluster, …
- 4/5-door versions: connector C541, pin 6,
circuit 31-LF20 (BK) (without a trailer socket)
or connector C2007, pin 6, circuit (GN) (with a
trailer socket) wiring harness side and
ground.
- Estate: connector C541d, pin 1, circuit 31-
LF11 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the right-
hand rear lamp cluster. CHECK the opera-
tion of the system.
→ No
REPAIR circuit (GN), 31-LF11 (BK) or 31-
LF20 (BK) between the rear lamp cluster
and ground connection G300 or G205 with
the aid of the Wiring Diagrams. CHECK
the operation of the system.
T8: CHECK CIRCUIT 15S-LD6 (GN/YE)
1 Key in OFF position.

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417-01-112 Exterior Lighting 417-01-112

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Left-hand rear lamp cluster.
- C540d estate
- C2005 (4/5-door versions with a trailer
socket)
3 Key in ON position.
4 Switch on the REAR FOG LAMPS.
5 Measure the voltage between the left-hand
rear lamp cluster, connector C540d, pin 3, cir-
cuit 15S-LD6 (GN/YE) (estate) or connector
C2005, pin 7, circuit (VT/YE) (4/5-door ver-
sions), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to T9
→ No
REPAIR circuit (VT/YE) or 15S-LD6
(GN/YE) with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
T9: CHECK CIRCUIT 31-LF11 (BK)
1 Key in OFF position.
2 Disconnect Left-hand rear lamp cluster C540
(4/5-door versions without a trailer socket).
3 Measure the resistance between the left-hand
rear lamp cluster, …
- 4/5-door versions: connector C540, pin 6,
circuit 31-LF11 (BK) (without a trailer socket)
or connector C2005, pin 6, circuit (BN) (with a
trailer socket) wiring harness side and
ground.
- Estate: connector C541d, pin 1, circuit 31-
LF11 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK and if necessary RENEW the left-
hand rear lamp cluster. CHECK the opera-
tion of the system.
→ No

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417-01-113 Exterior Lighting 417-01-113

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit (BN) or 31-LF11 (BK) be-
tween the rear lamp cluster and ground
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
PINPOINT TEST U: FOG LAMPS ON CONTINUOUSLY
CONDITIONS DETAILS/RESULTS/ACTIONS
U1: CHECK THE LIGHT SWITCH.
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Key in ON position.
4 Check the fog lamps.
• Are the fog lamps illuminated?
→ Yes
Rear fog lamps on continuously, vehicles
without a trailer socket: LOCATE and
RECTIFY the short circuit to voltage supply
in circuit 15S-LD16 (GN/RD), 15S-LD6
(GN/YE) or 15S-LD12 (GN/YE) between the
light switch and the rear fog lamp with the
aid of the Wiring Diagrams. CHECK the
operation of the system.
Rear fog lamps on continuously, vehicles
with a trailer socket: GO to U2
Front fog lamps on continuously: LOCATE
and RECTIFY the short to voltage supply in
circuit 15S-LD10 (GN/OG), 15S-LD9
(GN/BK), 15S-LD11 (GN/WH) or 15S-LD17
(GN/WH) between the light switch and the
front fog lamps with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
→ No
CHECK and if necessary RENEW the light
switch. CHECK the operation of the sys-
tem.
U2: CHECK THE REAR FOG LAMP SHUT-OFF RELAY
1 Key in OFF position.
2 Disconnect Rear fog lamp shut-off relay
C2008.
3 Key in ON position.
4 Check the fog lamps.
• Are the rear fog lamps illuminated?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in circuit (VT/YE) or 15S-LD6
(GN/YE) (estate) between the rear fog lamp
shut-off relay and the rear fog lamp with the
aid of the Wiring Diagrams. CHECK the
operation of the system.
→ No

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417-01-114 Exterior Lighting 417-01-114

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the short to voltage
supply in circuit 15S-LD16 (GN/RD), 15S-
LD6 (GN/YE), 15S-LD12 (GN/YE) or
(RD/WH) between the light switch and the
rear fog lamp shut-off relay with the aid of
the Wiring Diagrams. CHECK the
operation of the system.
If the concern persists, CHECK and if nec-
essary RENEW the rear fog lamp shut-off
relay. CHECK the operation of the system.

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417-01-115 Exterior Lighting 417-01-115

DIAGNOSIS AND TESTING

Reversing Lamps

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Diagnosis and Testing
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electricaldamage.
device
Visual Check
Electrical
• Fuse(s).
Terminal probe kit • Bulb(s).
29-011 A • Rear lamp cluster.
• Electrical connector(s).
• Switch(es).
• Wiring harness.
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 cause is not visually evident, verify the
symptom and referto the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Backup lamps are inoperative • Fuse(s). • GO to Pinpoint Test V
• Circuit(s).
• Central junction box (CJB).
• Transmission switch (MTX75).
• Transmission range sensor
(CD4E).
• The individual backup lamp is • Circuit(s). • GO to Pinpoint Test W
inoperative • Bulb.
• Trailer interface (TI) module
• Backup lamps are on continu- • Circuit(s). • GO to Pinpoint Test X
ously • Generic electronic module
(GEM).
• Transmission switch (MTX75).
• Transmission range sensor
(CD4E).
• Audio/navigation control unit.
• Trailer interface (TI) module

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.

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417-01-116 Exterior Lighting 417-01-116

DIAGNOSIS AND TESTING

PINPOINT TEST V: BACKUP LAMPS INOPERATIVE

CONDITIONS DETAILS/RESULTS/ACTIONS
V1: CHECK FUSE F80 (CJB)
1 Key in OFF position.
2 CHECK Fuse F80 (CJB).
3 Check the fuse F80 (7,5 A).
• Is the fuse OK?
→ Yes
GO to V2
→ No
Install a new fuse F80 (7,5 A). If the fuse
blows again, REPAIR the short circuit with
the aid of the wiring diagrams. CHECK the
operation of the system.
V2: MEASURE THE VOLTAGE AT FUSE F80
1 Connect Fuse F80 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F80 (CJB)
and ground.
• Is battery voltage indicated?
→ Yes
GO to V3
→ No
LOCATE and RECTIFY the break in the
voltage supply to fuse F80 with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
V3: DETERMINE MODEL VARIANT
1 Determine the model variant.
• Is the vehicle equipped with an automatic
transmission?
→ Yes
GO to V7
→ No
GO to V4
V4: CHECK CIRCUIT 15-LG28 (GN/WH)
1 Key in OFF position.
2 Disconnect Transmission switch C181.
3 Key in ON position.

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417-01-117 Exterior Lighting 417-01-117

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the transmission
switch, connector C181, pin 1, circuit 15-LG28
(GN/WH), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to V5
→ No
REPAIR circuit 15-LG28 (GN/WH) between
fuse F80 and the transmission switch with
the aid of the Wiring Diagrams. CHECK
the operation of the system.
V5: CHECK THE TRANSMISSION SWITCH
1 Key in OFF position.
2 Use a test cable to bridge the transmission
switch, connector C181, pin 1, circuit 15-LG28
(GN/WH) and pin 2, circuit 15S-LG9 (GN/BK),
wiring harness side.

3 Key in ON position.
4 If the concern persists, do not remove the
bridging cable on 4/5-door versions.
5 Check the backup lamps.
• Are the backup lamps lit up?
→ Yes
RENEW the transmission switch. Check
the operation of the system.
→ No
Estate: REPAIR circuit 15S-LG9 (GN/BK) or
15S-LG9A (GN/BK) between the transmis-
sion switch and soldered connection S232
with the aid of the Wiring Diagrams.
CHECK the operation of the system.

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417-01-118 Exterior Lighting 417-01-118

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4/5-door versions: GO to V6
V6: CHECK CIRCUITS 15S-LG9 (GN/BK) AND 15S-LG9A (GN/BK)
1 Depress the BRAKE.
2 Check the stoplamps.
• Do the stoplamps light up?
→ Yes
REPAIR circuit 15S-LG9 (GN/BK) and 15S-
LG9A (GN/BK) between the transmission
switch and the rear lamp cluster with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
→ No
REPAIR circuit 31-DA7 (BK) between sol-
dered connection S211 and ground con-
nection G300 with the aid of the wiring dia-
grams. CHECK the operation of the sys-
tem.
V7: CHECK THE CIRCUIT 15-LG28
1 Key in OFF position.
2 Disconnect Transmission range sensor C187.
3 Key in ON position.
4 Measure the voltage between connector C187,
pin 1, circuit 15-LG28 (GN/WH), wiring harness
side and ground.

• Is battery voltage indicated?

→ Yes
GO to V8
→ No
REPAIR circuit 15-LG28 (GN/WH) between
fuse F80 and the transmission range sen-
sor with the aid of the Wiring Diagrams.
CHECK the operation of the system.
V8: CHECK THE TRANSMISSION RANGE SENSOR
1 Key in OFF position.

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417-01-119 Exterior Lighting 417-01-119

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Use a test cable to bridge the transmission
range sensor, connector C187, pin 1, circuit
15-LG28 (GN/WH) and pin 3, circuit 15S-LG9
(GN/BK), wiring harness side.

3 Key in ON position.
4 If the concern persists, do not remove the
bridging cable on 4/5-door versions.
5 Check the backup lamps.
• Are the backup lamps lit up?
→ Yes
RENEW the transmission range sensor.
CHECK the operation of the system.
→ No
Estate: REPAIR circuit 15S-LG9 (GN/BK)
and 15S-LG9A (GN/BK) between the
transmission range sensor and soldered
connection S232 with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
4/5-door versions: GO to V9
V9: CHECK CIRCUITS 15S-LG9 (GN/BK), 15S-LG9A (GN/BK) AND (BK)
1 Key in ON position.
2 Depress the BRAKE.
3 Check the stoplamps.
• Do the stoplamps light up?
→ Yes
REPAIR circuits 15S-LG9 (GN/BK), 15S-
LG9A (GN/BK) and (BK) between the
transmission range sensor and the rear
lamp cluster with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
→ No
REPAIR circuit 31-DA7 (BK) between sol-
dered connection S211 and ground con-
nection G300 with the aid of the wiring dia-
grams. CHECK the operation of the sys-
tem.

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417-01-120 Exterior Lighting 417-01-120

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST W: INDIVIDUAL BACKUP LAMP INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
W1: DETERMINE THE INOPERATIVE LAMP
1 Key in ON position.
2 Shift the transmission into "Reverse".
3 Determine which backup lamp is inoperative.
• Is the left-hand backup lamp on the vehicle in-
operative?
→ Yes
Left-hand backup lamp, on the vehicle:
GO to W2
Left-hand backup lamp on the vehicle and
backup lamp on the trailer inoperative:
REPAIR circuit 15S-LG9 (GN/BK) between
soldered connection S232 and the rear
lamp cluster with the aid of the Wiring Dia-
grams. Check the operation of the system.
→ No
Right-hand backup lamp on the vehicle in-
operative: GO to W3
Backup lamp on the trailer inoperative:
GO to W4
W2: CHECK CIRCUITS 15S-LG9 (GN/BK) AND (BK)
1 Key in OFF position.
2 Disconnect Left-hand rear lamp cluster.
- C540 (4/5-door versions without a trailer
socket)
- C2005 (4/5-door versions with a trailer
socket)
- C540c estate
3 Key in ON position.
4 Shift the transmission into "Reverse".
5 Measure the voltage between the left-hand
rear lamp cluster, connector C540 (4/5-door
versions without a trailer socket), pin 5, con-
nector C540c (estates), pin 2, circuit 15S-LG9
(GN/BK) or C2005 (4/5-door versions with a
trailer socket), pin 5, circuit (BK) wiring harness
side and ground.

• Is battery voltage indicated?

→ Yes

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417-01-121 Exterior Lighting 417-01-121

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK and if necessary RENEW the rear
lamp cluster. CHECK the operation of the
system. If the concern persists, REPAIR
circuit 31-LF11 (BK) (4/5-door versions) or
31-LG9 (BK) (estates), between the rear
lamp cluster and ground connection G300
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
→ No
REPAIR circuit 15S-LG9 (GN/BK) between
soldered connection S232 and the rear
lamp cluster with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
W3: CHECK CIRCUIT 15S-LG16 (GN/OG), 15S-LG9 (GN/BK) OR (GN)
1 Key in OFF position.
2 Disconnect Left-hand rear lamp cluster.
- C541 (4/5-door versions without a trailer
socket)
- C2007 (4/5-door versions with a trailer
socket)
- C541c estate
3 Key in ON position.
4 Shift the transmission into "Reverse".
5 Measure the voltage between the right-hand
rear lamp cluster, connector C541 (4/5-door
versions without a trailer socket), pin 5, con-
nector C540c (estates), pin 2, circuit 15S-LG9
(GN/BK) or C2007 (4/5-door versions with a
trailer socket), pin 5, circuit (GN) wiring har-
ness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the rear
lamp cluster. CHECK the operation of the
system. REPAIR circuit 31-LF20 (BK) (4/5-
door versions) or 31-LG9 (BK) (estates) be-
tween the rear lamp cluster and ground
connection G300 (4/5-door versions) or
G205 (estates) with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
→ No

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417-01-122 Exterior Lighting 417-01-122

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 15S-LG16 (GN/OG), 15S-
LG9 (GN/BK) or (GN) between soldered
connection S232 and the rear lamp cluster
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
W4: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Shift the transmission into "Reverse".
5 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 9, cir-
cuit (BK), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to W5
→ No
REPAIR the circuit (BK) between connector
C2004 (4/5-door versions) or C2005 (es-
tates) and the trailer interface (TI) module
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
W5: CHECK CIRCUIT (VT/OG)
1 Key in OFF position.
2 Shift the transmission into "Reverse".
3 Measure the resistance between the trailer in-
terface (TI) module, connector C2000, pin 10,
circuit (VT/OG), wiring harness side and the
trailer socket, connector C2012, pin 8, circuit
(VT/OG), wiring harness side or the auxiliary
trailer socket, connector C2013, pin 1, circuit
(VT/OG), wiring harness side.

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417-01-123 Exterior Lighting 417-01-123

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 2 Ohm?

→ Yes
CHECK and if necessary RENEW the trailer
interface (TI) module. Check the operation
of the system.
→ No
REPAIR circuit (VT/OG) between the trailer
interface (TI) module and the auxiliary
trailer socket with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
PINPOINT TEST X: BACKUP LAMPS ARE ON CONTINUOUSLY
CONDITIONS DETAILS/RESULTS/ACTIONS
X1: CHECK THE TRANSMISSION SWITCH/TRANSMISSION RANGE SENSOR
1 Key in OFF position.
2 Disconnect Transmission switch C181 or
transmission range sensor C187.
3 Key in ON position.
4 Check if the lamps are still on continuously.
• Are the backup lamps on continuously?
→ Yes
GO to X2
→ No
Vehicles with manual transmission RENEW
the transmission switch. CHECK the op-
eration of the system.
Vehicles with automatic transmission:
RENEW the transmission range sensor.
CHECK the operation of the system.
X2: ELIMINATE MODULES/COMPONENTS AS THE POSSIBLE CAUSE FOR A SHORT CIRCUIT
TO BATTERY VOLTAGE
1 Key in OFF position.
2 Disconnect Start with the first module, then
proceed with the next test step (3 and 4)..
- (2.0 l diesel, 130 HP only): Powertrain control
module (PCM) C100
- Interior mirror with automatic glare adjustment
C473
- Parking aid module C2100a
- GEM module C428
- Audio/navigation control unit C485
- Trailer interface (TI) module
3 Key in ON position.
4 Check the backup lamps
• Are the backup lamps on?
→ Yes

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417-01-124 Exterior Lighting 417-01-124

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Not all of the listed modules have been dis-
connected: Switch off the ignition. Discon-
nect the next module, then proceed with test
step 2.
All of the listed modules have been discon-
nected: LOCATE and RECTIFY the short to
voltage supply in the circuits connected to
soldered connection S232 with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
→ No
RENEW the last component that was dis-
connected. CHECK the operation of the
system.

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417-01-125 Exterior Lighting 417-01-125

DIAGNOSIS AND TESTING

Trailer Lamps

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Diagnosis and Testing
Special Tool(s)
1. Check the customer concern.
Digital multimeter 2. Visually check for any obvious mechanical or
105-R0051 or a comparable electrical damage.
device
Visual Inspection
Electrical
• Fuse(s)
Terminal probe kit • Bulb(s)
29-011 A • Connector(s)
• Trailer socket
• Trailer lamps
• Wiring harness
3. Resolve any obvious causes for a concern
found during the visual inspection before
carrying out any further tests.
4. If the concern persists, check the symptoms
and continue with the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Trailer lamps inoperative • Fuse(s) • GO to Pinpoint Test Y
• Circuit(s) in the vehicle
• Circuit(s) in the trailer
• Trailer socket
• Trailer interface (TI) module
• Trailer switch interface (SI)
module
• Rear fog lamp shut-off relay
• Central junction box (CJB)
• One individual trailer lamp inop- • Circuit(s) in the vehicle • GO to Pinpoint Test Z
erative • Circuit(s) in the trailer
• Trailer interface (TI) module
• Trailer switch interface (SI)
module
• Trailer lamps permanently on • Circuit(s) in the vehicle • GO to Pinpoint Test AA
• Circuit(s) in the trailer
• Trailer socket
• Trailer interface (TI) module
• Trailer switch interface (SI)
module

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417-01-126 Exterior Lighting 417-01-126

DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests
PINPOINT TEST Y: TRAILER LAMPS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
Y1: DETERMINE WHICH LAMPS ON THE TRAILER ARE INOPERATIVE
1 Key in ON position.
2 Switch on the SIDE LIGHTS, STOPLAMPS,
REAR FOG LAMPS and LEFT and RIGHT-
HAND TURN SIGNAL LAMPS in turn. Engage
reverse gear.
3 Check the trailer lamps.
• Are all of the lamps on the trailer inoperative?
→ Yes
GO to Y2
→ No
Only the rear lamps inoperative: RENEW
the trailer interface (TI) module. CHECK
the operation of the system.
Stoplamps and turn signal lamps inopera-
tive: GO to Y7
Only the stoplamps inoperative: GO to Y9
Only the backup lamp(s) inoperative:
GO to Y14
Only the rear fog lamp(s) inoperative:
GO to Y17
Only the turn signal lamps inoperative (both
sides): RENEW the trailer switch interface
(SI) module. CHECK the operation of the
system.
Y2: CHECK THE GROUND CONNECTION AT THE TRAILER SOCKET
1 Key in OFF position.

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417-01-127 Exterior Lighting 417-01-127

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
- 7-pin trailer socket, C2010, pin 3, circuit (BN)
and ground.
- 13-pin trailer socket, C2012, pin 3, circuit
(BN/WH) and ground and between pin 13,
circuit (BN) and ground.

• Is the resistance less than 2 Ohms?

→ Yes
GO to Y3
→ No
RECTIFY the open circuit in the circuit (BN)
or (BN/WH) between the trailer socket and
ground connection G302, G303 or G300
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
Y3: CHECK FUSE F74 (CJB)
1 CHECK Fuse F74 (CJB).
2 Check fuse F74 (20 A)
• Is the fuse OK?
→ Yes
GO to Y4
→ No
RENEW fuse F74 (20 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and REPAIR the short to
ground with the aid of the Wiring Diagrams.
Y4: CHECK THE VOLTAGE AT FUSE F74 (CJB)
1 Connect Fuse F74 (CJB).
2 Key in ON position.

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417-01-128 Exterior Lighting 417-01-128

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between fuse F74 (20 A)
and ground.
• Is battery voltage displayed?
→ Yes
GO to Y5
→ No
CHECK and if necessary RENEW the cen-
tral junction box (CJB). CHECK the opera-
tion of the system.
Y5: CHECK THE POWER SUPPLY TO THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 2, cir-
cuit (RD), wiring harness side and ground.

• Is battery voltage displayed?

→ Yes
GO to Y6
→ No
REPAIR the open circuit between fuse F74
(CJB) and the trailer interface (TI) module
with the aid of the Wiring Diagrams, and if
necessary RENEW the central junction box
(CJB). CHECK the operation of the sys-
tem.
Y6: CHECK THE GROUND CONNECTION OF THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.

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417-01-129 Exterior Lighting 417-01-129

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the trailer in-
terface (TI) module, connector C2000, pin 1,
circuit (BN), wiring harness side and ground.

• Is the resistance less than 2 ohm?

→ Yes
Continue troubleshooting on the trailer. If
the electrical system on the trailer is OK,
RENEW the trailer interface (TI) module.
CHECK that the system operates correctly.
→ No
REPAIR the open circuit between the trailer
interface (TI) module and soldered connec-
tion S811 (ground connection G300) with
the aid of the Wiring Diagrams. CHECK
the operation of the system.
Y7: CHECK THE POWER SUPPLY TO THE TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Key in ON position.
4 Measure the voltage between the trailer switch
interface (SI) module, connector C2002, pin 1,
circuit (RD), wiring harness side and ground.

• Is battery voltage displayed?

→ Yes
GO to Y8
→ No

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417-01-130 Exterior Lighting 417-01-130

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit between soldered
connection S810 (fuse F74 (CJB)) and the
trailer switch interface (SI) module with the
aid of the Wiring Diagrams. CHECK that
the system operates correctly.
Y8: CHECK THE GROUND CONNECTION OF THE TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Measure the resistance between the trailer
switch interface (SI) module, connector C2002,
pin 3, circuit (BN), wiring harness side and
ground.

• Is the resistance less than 2 ohm?

→ Yes
RENEW the trailer switch interface (SI)
module. CHECK the operation of the sys-
tem.
→ No
REPAIR the open circuit between the trailer
switch interface (SI) module and soldered
connection S811 (ground connection G300)
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
Y9: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE STOPLAMPS SWITCHED ON
1 Key in ON position.
2 Depress the BRAKE.

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417-01-131 Exterior Lighting 417-01-131

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 6, circuit (VT) and ground.

• Is battery voltage displayed?

→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Y10
Y10: CHECK THE VOLTAGE AT THE TRAILER INTERFACE (TI) MODULE WITH THE
STOPLAMPS SWITCHED ON
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Depress the BRAKE.

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417-01-132 Exterior Lighting 417-01-132

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 7, cir-
cuit (BK/RD), wiring harness side and ground.

• Is battery voltage displayed ?

→ Yes
GO to Y11
→ No
REPAIR the break in circuit (BK/RD) be-
tween connector C2004 and the trailer in-
terface (TI) module with the aid of the Wiring
Diagrams. CHECK that the system oper-
ates correctly.
Y11: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Use a fused test cable (10 A) to bridge the
trailer interface (TI) module, connector C2000,
pin 7, circuit (BK/RD) and pin 8, circuit
(BK/YE), wiring harness side.

3 Key in ON position.
4 Depress the BRAKE.

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417-01-133 Exterior Lighting 417-01-133

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 6, circuit (VT) and ground.

• Is battery voltage displayed?

→ Yes
RENEW the trailer interface (TI) module.
CHECK the operation of the system.
→ No
GO to Y12
Y12: CHECK THE CIRCUIT BETWEEN THE TRAILER INTERFACE (TI) MODULE AND THE
TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Measure the resistance between the trailer in-
terface (TI) module, connector C2000, pin 8,
circuit (BK/YE), wiring harness side and the
trailer switch interface (SI) module, connector
C2002, pin 4, circuit (BK/YE), wiring harness
side.

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417-01-134 Exterior Lighting 417-01-134

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 2 ohm?

→ Yes
GO to Y13
→ No
REPAIR the break in circuit (BK/YE) be-
tween the trailer interface (TI) module and
the trailer switch interface module (SI) with
the aid of the Wiring Diagrams. CHECK
the operation of the system.
Y13: CHECK THE CIRCUIT BETWEEN THE TRAILER SWITCH INTERFACE (SI) MODULE AND
THE TRAILER SOCKET
1 Measure the resistance between the trailer
switch interface (SI) module, connector C2002,
pin 2, circuit (VT), wiring harness side and the
trailer socket C2010 or C2012, pin 6, circuit
(VT).

• Is the resistance less than 2 ohm?

→ Yes
RENEW the trailer switch interface (SI)
module. CHECK that the system operates
correctly.
→ No
REPAIR the break in circuit (VT) between
the trailer switch interface (SI) module and
the trailer socket with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
Y14: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE BACKUP LAMPS SWITCHED
ON
1 Key in ON position.
2 Engage reverse gear.

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417-01-135 Exterior Lighting 417-01-135

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between
- 7-pin auxiliary trailer socket C2013, pin 1,
circuit (VT/OG) and ground.
- 13-pin trailer socket C2012, pin 8, circuit
(VT/OG) and ground.

• Is battery voltage displayed?

→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Y15
Y15: CHECK THE VOLTAGE AT THE TRAILER INTERFACE (TI) MODULE WITH THE BACKUP
LAMPS SWITCHED ON
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Engage reverse gear.

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417-01-136 Exterior Lighting 417-01-136

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 9, cir-
cuit (BK), wiring harness side and ground.

• Is battery voltage displayed?

→ Yes
GO to Y16
→ No
REPAIR the break in circuit (BK) between
connector C2004 and the trailer interface
(TI) module with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
Y16: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Use a fused test cable (7.5 A) to bridge the
trailer interface (TI) module, connector C2000,
pin 9, circuit (BK) and pin 10, circuit (VT/OG),
wiring harness side.

3 Key in ON position.
4 Engage reverse gear.

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417-01-137 Exterior Lighting 417-01-137

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between
- 7-pin auxiliary trailer socket C2013, pin 1,
circuit (VT/OG) and ground.
- 13-pin trailer socket C2012, pin 8, circuit
(VT/OG) and ground.

• Is battery voltage displayed?

→ Yes
RENEW the trailer interface (TI) module.
CHECK that the system operates correctly.
→ No
REPAIR the break in circuit (VT/OG) be-
tween the trailer interface (TI) module and
the trailer socket with the aid of the Wiring
Diagrams. CHECK that the system oper-
ates correctly.
Y17: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE REAR FOGLAMPS
SWITCHED ON
1 Key in ON position.
2 Switch on the REAR FOG LAMPS.

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417-01-138 Exterior Lighting 417-01-138

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 2, circuit (RD/YE) and ground.

• Is battery voltage displayed?

→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Y18
Y18: CHECK THE GROUND CONNECTION OF THE REAR FOG LAMP SHUT-OFF RELAY
1 Key in OFF position.
2 Disconnect Rear fog lamp shut-off relay
C2008.
3 Measure the resistance between the rear fog
lamp shut-off relay, connector C2008, circuit
(BN), wiring harness side and ground.

• Is the resistance less than 2 ohm?

→ Yes
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417-01-139 Exterior Lighting 417-01-139

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to Y19
→ No
REPAIR the break in circuit (BN) between
the rear fog lamp shut-off relay and sol-
dered connection S811 (ground connection
G300) with the aid of the Wiring Diagrams.
CHECK the operation of the system.
Y19: CHECK THE REAR FOG LAMP SHUT-OFF RELAY
1 Use a fused test cable (15 A) to bridge the rear
fog lamp shut-off relay, connector C2008, cir-
cuit (RD/WH) and circuit (RD/YE), wiring har-
ness side.

2 Key in ON position.
3 Switch on the REAR FOG LAMPS.
4 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 2, circuit (RD/YE) and ground.

• Is battery voltage displayed?

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417-01-140 Exterior Lighting 417-01-140

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
RENEW the rear fog lamp shut-off relay
CHECK the operation of the system.
→ No
REPAIR the break in circuit (RD/YE) be-
tween the rear fog lamp shut-off relay and
the trailer socket with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
PINPOINT TEST Z: ONE INDIVIDUAL TRAILER LAMP INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
Z1: DETERMINE WHICH LAMP IS INOPERATIVE
1 Key in ON position.
2 Check the trailer lamps.
• Is one of the rear lamps on the trailer inopera-
tive?
→ Yes
Left-hand rear trailer lamp inoperative:
GO to Z2
Right-hand rear trailer lamp inoperative:
GO to Z5
→ No
Trailer stoplamps inoperative: GO to Y9
Trailer backup lamp(s) inoperative:
GO to Y14
Trailer rear fog lamp(s) inoperative:
GO to Y17
Left-hand trailer turn signal lamp inopera-
tive: GO to Z8
Right-hand trailer turn signal lamp inopera-
tive: GO to Z10
Z2: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE SIDE LIGHTS SWITCHED ON
1 Switch on the side lights.

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417-01-141 Exterior Lighting 417-01-141

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 7, circuit (OG/WH) and ground.

• Is battery voltage displayed?

→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Z3
Z3: CHECK THE VOLTAGE AT THE TRAILER INTERFACE (TI) MODULE WITH THE SIDE LIGHTS
SWITCHED ON
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 3, cir-
cuit (GY/BK), wiring harness side and ground.

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417-01-142 Exterior Lighting 417-01-142

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage displayed?

→ Yes
GO to Z4
→ No
REPAIR the break in circuit (GY/BK) be-
tween connector C2004 and the trailer in-
terface (TI) module with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
Z4: CHECK THE CIRCUIT BETWEEN THE TRAILER INTERFACE (TI) MODULE AND THE
TRAILER SOCKET
1 Key in OFF position.
2 Measure the resistance between the trailer
socket C2010 (7-pin socket) or C2012 (13-pin
socket), pin 7, circuit (OG/WH) and the trailer
interface (TI) module, connector C2000, pin 4,
circuit (OG/WH), wiring harness side.

• Is the resistance less than 2 ohm?

→ Yes
RENEW the trailer interface (TI) module.
CHECK the operation of the system.
→ No
REPAIR the break in circuit (OG/WH) be-
tween the trailer interface (TI) module and
the trailer socket with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
Z5: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE SIDE LIGHTS SWITCHED ON
1 Switch on the side lights.

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417-01-143 Exterior Lighting 417-01-143

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 5, circuit (OG) and ground.

• Is battery voltage displayed?

→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Z6
Z6: CHECK THE VOLTAGE AT THE TRAILER INTERFACE (TI) MODULE WITH THE SIDE LIGHTS
SWITCHED ON
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Key in ON position.
4 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 5, cir-
cuit (GY/RD), wiring harness side and ground.

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417-01-144 Exterior Lighting 417-01-144

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage displayed?

→ Yes
GO to Z7
→ No
REPAIR the break in circuit (GY/RD) be-
tween connector C2004 and the trailer in-
terface (TI) module with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
Z7: CHECK THE CIRCUIT BETWEEN THE TRAILER INTERFACE (TI) MODULE AND THE
TRAILER SOCKET
1 Key in OFF position.
2 Measure the resistance between the trailer
socket C2010 (7-pin socket) or C2012 (13-pin
socket), pin 5, circuit (OG) and the trailer inter-
face (TI) module, connector C2000, pin 6, cir-
cuit (OG), wiring harness side.

• Is the resistance less than 2 ohm?

→ Yes
RENEW the trailer interface (TI) module.
CHECK the operation of the system.
→ No
REPAIR the break in circuit (OG) between
the trailer interface (TI) module and the
trailer socket with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
Z8: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE LEFT-HAND TURN SIGNAL
SWITCHED ON
1 Key in ON position.
2 Switch on the LEFT-HAND TURN SIGNAL.

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417-01-145 Exterior Lighting 417-01-145

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 1, circuit (BU) and ground.

• Does the voltage alternate between 0 V and

battery voltage?
→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Z9
Z9: CHECK THE CIRCUIT BETWEEN THE TRAILER SWITCH INTERFACE (SI) MODULE AND
THE TRAILER SOCKET
1 Key in OFF position.
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Measure the resistance between the trailer
socket C2010 (7-pin socket) or C2012 (13-pin
socket), pin 1, circuit (BU) and the trailer switch
interface (SI) module, connector C2002, pin 7,
circuit (BU), wiring harness side.

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417-01-146 Exterior Lighting 417-01-146

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 2 ohm?

→ Yes
RENEW the trailer switch interface (SI)
module. CHECK the operation of the sys-
tem.
→ No
REPAIR the break in circuit (BU) between
the trailer switch interface (SI) module and
the trailer socket with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
Z10: CHECK THE VOLTAGE AT THE TRAILER SOCKET WITH THE RIGHT-HAND TURN SIGNAL
SWITCHED ON
1 Key in ON position.
2 Switch on the RIGHT-HAND TURN SIGNAL.
3 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 4, circuit (BU/RD) and ground.

• Does the voltage alternate between 0 V and

battery voltage?
→ Yes
Continue troubleshooting on the trailer.
→ No
GO to Z11
Z11: CHECK THE CIRCUIT BETWEEN THE TRAILER SWITCH INTERFACE (SI) MODULE AND
THE TRAILER SOCKET
1 Key in OFF position.

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417-01-147 Exterior Lighting 417-01-147

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Trailer switch interface (SI) module
C2002.
3 Measure the resistance between the trailer
socket C2010 (9-pin socket) or C2012 (13-pin
socket), pin 4, circuit (BU/RD) and the trailer
switch interface (SI) module, connector C2002,
pin 9, circuit (BU/RD), wiring harness side.

• Is the resistance less than 2 ohm?

→ Yes
RENEW the trailer switch interface (SI)
module. CHECK the operation of the sys-
tem.
→ No
REPAIR the break in circuit (BU/RD) be-
tween the trailer switch interface (SI) mod-
ule and the trailer socket with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
PINPOINT TEST AA: TRAILER LAMPS PERMANENTLY ON
CONDITIONS DETAILS/RESULTS/ACTIONS
AA1: CHECK THE FAULT SYMPTOMS
1 Key in ON position.
2 Check the trailer lamps.
• Is/are the rear fog lamp(s) on the trailer per-
manently on?
→ Yes
GO to AA2
→ No
Rear trailer lamp(s) permanently on:
GO to AA3
Trailer stoplamps permanently on:
GO to AA7
Trailer backup lamps permanently on:
GO to AA11
Trailer turn signal lamp(s) permanently on:
GO to AA13

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417-01-148 Exterior Lighting 417-01-148

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AA2: CHECK FOR SHORT TO BATTERY VOLTAGE AT THE TRAILER SOCKET (REAR FOG
LAMP)
1 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 2, circuit (RD/YE) and ground.

• Is battery voltage displayed?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (RD/YE) between the
rear fog lamp shut-off relay and the trailer
socket with the aid of the Wiring Diagrams,
and RENEW the trailer socket as required.
CHECK the operation of the system.
→ No
Continue troubleshooting on the trailer.

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417-01-149 Exterior Lighting 417-01-149

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AA3: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (LEFT-HAND REAR
LAMP)
1 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 7, circuit (OG/WH) and ground.

• Is battery voltage displayed?

→ Yes
GO to AA5
→ No
GO to AA4

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417-01-150 Exterior Lighting 417-01-150

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AA4: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (RIGHT-HAND REAR
LAMP)
1 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 5, circuit (OG) and ground.

• Is battery voltage displayed?

→ Yes
GO to AA6
→ No
Continue troubleshooting on the trailer.
AA5: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Fuse F74 (CJB).
3 Key in ON position.

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417-01-151 Exterior Lighting 417-01-151

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 7, circuit (OG/WH) and ground.

• Is battery voltage displayed in one of the

measurements?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (OG/WH) between the
trailer interface (TI) module and the trailer
socket with the aid of the Wiring Diagrams,
and RENEW the trailer socket as required.
CHECK the operation of the system.
→ No
RENEW the trailer interface (TI) module.
CHECK the operation of the system.
AA6: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Fuse F74 (CJB).
3 Key in ON position.

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417-01-152 Exterior Lighting 417-01-152

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 5, circuit (OG) and ground.

• Is battery voltage displayed in one of the

measurements?
→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (OG) between the
trailer interface (TI) module and the trailer
socket with the aid of the Wiring Diagrams,
and RENEW the trailer socket as required.
CHECK the operation of the system.
→ No
RENEW the trailer interface (TI) module.
CHECK the operation of the system.

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417-01-153 Exterior Lighting 417-01-153

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AA7: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (STOPLAMPS)
1 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 6, circuit (VT) and ground.

• Is battery voltage displayed?

→ Yes
GO to AA8
→ No
Continue troubleshooting on the trailer.
AA8: NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE
1 Key in OFF position.
2 Disconnect Fuse F74 (CJB).
3 Key in ON position.

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417-01-154 Exterior Lighting 417-01-154

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 6, circuit (VT) and ground.

• Is battery voltage displayed?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (VT) between the
trailer switch interface (SI) module and the
trailer socket with the aid of the Wiring Dia-
grams, and RENEW the trailer socket as re-
quired. CHECK the operation of the sys-
tem.
→ No
GO to AA9
AA9: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Trailer interface (TI) module
C2000.
3 Connect Fuse F74 (CJB).
4 Key in ON position.

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417-01-155 Exterior Lighting 417-01-155

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 6, circuit (VT) and ground.

• Is battery voltage displayed?

→ Yes
GO to AA10
→ No
RENEW the trailer interface (TI) module.
CHECK the operation of the system.
AA10: CHECK THE CIRCUIT BETWEEN THE TRAILER INTERFACE (TI) MODULE AND THE
TRAILER SWITCH INTERFACE (SI) MODULE
1 Measure the voltage between the trailer inter-
face (TI) module, connector C2000, pin 8, cir-
cuit (BK/YE), wiring harness side and ground.

• Is battery voltage displayed?

→ Yes

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417-01-156 Exterior Lighting 417-01-156

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the short to battery
voltage in circuit (BK/YE) between the
trailer interface (TI) module and the trailer
switch interface module (SI) with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
→ No
RENEW the trailer switch interface (SI)
module. CHECK the operation of the sys-
tem.
AA11: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (BACKUP LAMP(S))
1 Measure the voltage between
- 7-pin auxiliary trailer socket C2013, pin 1,
circuit (VT/OG) and ground.
- 13-pin trailer socket C2012, pin 8, circuit
(VT/OG) and ground.

• Is battery voltage displayed?

→ Yes
GO to AA12
→ No
Continue troubleshooting on the trailer.
AA12: CHECK THE TRAILER INTERFACE (TI) MODULE
1 Key in OFF position.
2 Disconnect Fuse F74 (CJB).
3 Key in ON position.

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417-01-157 Exterior Lighting 417-01-157

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between
- 7-pin auxiliary trailer socket C2013, pin 1,
circuit (VT/OG) and ground.
- 13-pin trailer socket C2012, pin 8, circuit
(VT/OG) and ground.

• Is battery voltage displayed?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (VT/OG) between the
trailer interface (TI) module and the trailer
socket with the aid of the Wiring Diagrams,
and RENEW the trailer socket as required.
CHECK that the system operates correctly.
→ No
RENEW the trailer interface (TI) module.
CHECK the operation of the system.

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417-01-158 Exterior Lighting 417-01-158

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AA13: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (LEFT-HAND TURN
SIGNAL LAMP)
1 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 1, circuit (BU) and ground.

• Is battery voltage displayed ?

→ Yes
GO to AA15
→ No
GO to AA14

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417-01-159 Exterior Lighting 417-01-159

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AA14: CHECK FOR A SHORT TO BATTERY VOLTAGE ON THE VEHICLE (RIGHT-HAND TURN
SIGNAL LAMP)
1 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 4, circuit (BU/RD) and ground.

• Is battery voltage displayed?

→ Yes
GO to AA16
→ No
Continue troubleshooting on the trailer.
AA15: CHECK THE TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Disconnect Fuse F74 (CJB).
3 Key in ON position.

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417-01-160 Exterior Lighting 417-01-160

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 1, circuit (BU) and ground.

• Is battery voltage displayed?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (BU) between the
trailer switch interface (SI) module and the
trailer socket with the aid of the Wiring Dia-
grams, and RENEW the trailer socket as re-
quired. CHECK the operation of the sys-
tem.
→ No
RENEW the trailer switch interface (SI)
module. CHECK the operation of the sys-
tem.
AA16: CHECK THE TRAILER SWITCH INTERFACE (SI) MODULE
1 Key in OFF position.
2 Disconnect Fuse F74 (CJB).
3 Key in ON position.

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417-01-161 Exterior Lighting 417-01-161

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the trailer socket
C2010 (7-pin socket) or C2012 (13-pin socket),
pin 4, circuit (BU/RD) and ground.

• Is battery voltage displayed?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in the circuit (BU/RD) between the
trailer switch interface (SI) module and the
trailer socket with the aid of the Wiring Dia-
grams, and RENEW the trailer socket as re-
quired. CHECK the operation of the sys-
tem.
→ No
RENEW the trailer switch interface (SI)
module. CHECK the operation of the sys-
tem.

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417-01-162 Exterior Lighting 417-01-162

DIAGNOSIS AND TESTING

Headlamp Leveling

Refer to Wiring Diagrams Section 417-01 for

schematic and connector information.
Diagnosis and testing
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electricaldamage.
device
Visual inspection
Electrical
• Fuse(s).
Terminal probe kit • Wiring harness.
29-011 A • Electrical connector(s).
• Switch(es).
• Sensors
• Headlamps
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 cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Headlamp levelling system in- • Fuse(s). • GO to Pinpoint Test AB
operative / not functioning prop- • Circuit(s).
erly, conventional headlamps • Light switch
• Headlamp levelling switch.
• Headlamp levelling motor.
• Headlamp levelling system in- • Fuse(s). • GO to Pinpoint Test AC
operative / not functioning prop- • Circuit(s).
erly, Xenon headlamps • Headlamp levelling motor.
• Headlamp levelling sensor
• Headlamps

Pinpoint Tests
PINPOINT TEST AB: HEADLAMP LEVELLING SYSTEM INOPERATIVE / NOT FUNCTIONING
PROPERLY, CONVENTIONAL HEADLAMPS
CONDITIONS DETAILS/RESULTS/ACTIONS
AB1: CHECK THE HEADLAMP LEVELLING SWITCH
1 Key in ON position.
2 Switch on the dipped beam.
3 Move the headlamp levelling switch from posi-
tion "4" to "1".
4 Check the adjustment of the headlamps.

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417-01-163 Exterior Lighting 417-01-163

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the headlamp levelling system inoperative

on both headlamps?
→ Yes
GO to AB2
→ No
Left-hand side is inoperative: GO to AB4
Right-hand side is inoperative: GO to AB9
AB2: CHECK THE LIGHT SWITCH.
1 Key in OFF position.
2 Disconnect Light switch (C478).
3 Check the light switch in accordance with the
Component Checks in the Wiring Diagrams.
• Is the light switch OK?
→ Yes
GO to AB3
→ No
RENEW the light switch. CHECK the op-
eration of the system.
AB3: CHECK CIRCUIT 31-LE29 (BK)
1 Measure the resistance between the light
switch, connector C478, pin 10, circuit 31-LE29
(BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
REPAIR circuit 64-LE45 (BU) between the
light switch and the headlamp with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
→ No
REPAIR circuit 31-LE29 (BK) between the
light switch and ground connection G204
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AB4: CHECK FUSE F64 (CJB)
1 Key in OFF position.
2 CHECK Fuse F64 (CJB).
3 Check fuse F64 (7.5 A)
• Is the fuse OK?

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417-01-164 Exterior Lighting 417-01-164

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to AB5
→ No
INSTALL a new fuse F64 (7.5 A). If the
fuse blows again, LOCATE and RECTIFY
the short circuit with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
AB5: CHECK CIRCUIT 29S-LF7 (OG/BU)
1 Connect Fuse F64 (CJB).
2 Disconnect Left-hand headlamp C146.
3 Disconnect CJB C509.
4 Measure the resistance between CJB, connec-
tor C509, pin 6, circuit 29S-LF7(OG/BU), har-
ness side and left-hand headlamp, connector
C146, pin 4, circuit 29S-LF7(OG/BU), harness
side.

• Is the resistance less than 2 ohms?

→ Yes
GO to AB6
→ No
REPAIR circuit 29S-LF7 (OG/BU) between
fuse F64 and the left-hand headlamp with
the aid of the Wiring Diagrams. CHECK
the operation of the system.
AB6: CHECK CIRCUIT 64-LE45 (BU)
1 Disconnect Light switch (C478).
2 Measure the resistance between the left-hand
headlamp, connector C146, pin 5, circuit 64-
LE45 (BU), wiring harness side and the light
switch, connector C478, pin 1, circuit 64-LE45
(BU), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
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417-01-165 Exterior Lighting 417-01-165

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to AB7
→ No
REPAIR circuit 64-LE45 (BU) between the
headlamp and the light switch with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
AB7: CHECK CIRCUIT 31-LE31 (BK)
1 Measure the resistance between the left-hand
headlamp, connector C146, pin 7, circuit 31-
LE31 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to AB8
→ No
REPAIR circuit 31-LE31 (BK) between the
headlamp and ground connection G104
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AB8: CHECK THE LEFT-HAND HEADLAMP LEVELLING MOTOR
1 Remove the left-hand headlamp.
2 Disconnect Left-hand headlamp levelling mo-
tor.
3 Measure the resistance at the left-hand head-
lamp between connector C146, pin 5, circuit
(BU), component side and the headlamp level-
ling motor, circuit (BU), wiring harness side.

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417-01-166 Exterior Lighting 417-01-166

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between the left-hand
headlamp, connector C146, pin 7, circuit (BK),
component side and the left-hand headlamp
levelling motor, circuit (BK), wiring harness
side.

5 Measure the resistance at the left-hand head-

lamp between connector C146, pin 4, circuit
(VT/YE), component side and the headlamp
levelling motor, circuit (VT/YE), wiring harness
side.

• Is the resistance in all three measurements

less than 2 ohms?
→ Yes
CHECK and if necessary RENEW the left-
hand headlamp levelling motor. CHECK
the operation of the system.
→ No
REPAIR the affected circuit between the
headlamp levelling motor and the headlamp
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AB9: CHECK FUSE F63 (CJB)
1 Key in OFF position.
2 CHECK Fuse F63 (CJB).
3 Check the fuse F63 (7.5 A) (CJB).
• Is the fuse OK?
→ Yes
GO to AB10
→ No
INSTALL a new fuse F63 (7.5 A). If the
fuse blows again, LOCATE and RECTIFY
the short circuit with the aid of the Wiring
Diagrams. CHECK the operation of the
system.

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417-01-167 Exterior Lighting 417-01-167

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AB10: CHECK CIRCUIT 29S-LF16 (OG/GN)
1 Disconnect Right-hand headlamp C147.
2 Disconnect CJB C509.
3 Measure the resistance between the CJB,
connector C509, pin 7, circuit 29S-LF16
(OG/GN), wiring harness side and the right-
hand headlamp, connector C147, pin 4, circuit
29S-LF16 (OG/GN), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to AB11
→ No
REPAIR circuit 29S-LF16 (OG/GN) between
fuse F63 and the headlamp with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
AB11: CHECK CIRCUIT 64-LE46 (BU/RD)
1 Disconnect Light switch (C478).
2 Measure the resistance between the right-hand
headlamp, connector C147, pin 5, circuit 64-
LE46 (BU/RD), wiring harness side and the
light switch, connector C478, pin 1, circuit 64-
LE45 (BU), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to AB12
→ No
REPAIR circuit 64-LE46 (BU/RD) between
the light switch and the headlamp with the
aid of the Wiring Diagrams. CHECK the
operation of the system.

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417-01-168 Exterior Lighting 417-01-168

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AB12: CHECK CIRCUIT 31-LE30 (BK)
1 Measure the resistance between Right-hand
headlamp, connector C147, pin 7, circuit31-
LE30 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to AB13
→ No
REPAIR circuit 31-LE30 (BK) between the
headlamp and ground connection G105
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AB13: CHECK RIGHT-HAND HEADLAMP LEVELLING MOTOR
1 Remove the right-hand headlamp.
2 Disconnect Right-hand headlamp levelling mo-
tor.
3 Measure the resistance at the right-hand head-
lamp between connector C147, pin 5, circuit
(BU), component side and the headlamp level-
ling motor, circuit (BU), wiring harness side.

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417-01-169 Exterior Lighting 417-01-169

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance at the right-hand head-
lamp between connector C147, pin 7, circuit
(BK), component side and the headlamp level-
ling motor, circuit (BK), wiring harness side.

5 Measure the resistance at the right-hand head-

lamp between connector C147, pin 4, circuit
(VT/YE), component side and the headlamp
levelling motor, circuit (VT/YE), wiring harness
side.

• Is the resistance in all three measurements

less than 2 ohms?
→ Yes
CHECK and if necessary RENEW the right-
hand headlamp levelling motor. CHECK
the operation of the system.
→ No
REPAIR the affected circuit between the
headlamp levelling motor and the headlamp
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
PINPOINT TEST AC: HEADLAMP LEVELLING SYSTEM INOPERATIVE / NOT FUNCTIONING
PROPERLY, XENON HEADLAMPS
CONDITIONS DETAILS/RESULTS/ACTIONS
AC1: READ OUT THE FAULT MEMORY
1 Key in OFF position.
2 Connect the diagnostic tool.
3 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.

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417-01-170 Exterior Lighting 417-01-170

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
GO to AC2
AC2: DETERMINE THE FAULT CONDITION
NOTE: On vehicles with Xenon headlamps the headlamp levelling takes place automatically according
to the loading of the vehicle. The basic settings should be performed once on an unladen vehicle with
the aid of WDS.
1 Key in ON position.
2 Switch on the dipped beam.
3 Simulation of a laden/unladen vehicle.
4 Check the operation of the headlamp levelling
system.
• Is the headlamp levelling system inoperative
on both sides?
→ Yes
GO to AC3
→ No
Headlamp levelling system inoperative on
the left-hand side: GO to AC19
Headlamp levelling system inoperative on
the right-hand side: GO to AC22
AC3: CHECK FUSE F93 (CJB)
1 Key in OFF position.
2 CHECK Fuse F93 (CJB).
3 Check fuse F93 (10 A)
• Is the fuse OK?
→ Yes
GO to AC4
→ No
INSTALL a new fuse F93 (10 A). If the fuse
blows again, LOCATE and RECTIFY the
short circuit with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
AC4: CHECK CIRCUIT 15-LE2 (GN/BU)
1 Key in OFF position.
2 Connect Fuse F93.
3 Disconnect Left-hand headlamp C1146.
4 Key in ON position.
5 Switch on the dipped beam.

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417-01-171 Exterior Lighting 417-01-171

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Measure the voltage between the left-hand
headlamp, connector C1146, pin 5, circuit 15-
LE2A (GN/BU), wiring harness side and
ground.

• Is battery voltage displayed?

→ Yes
GO to AC5
→ No
REPAIR circuit 15-LE2 (GN/BU) between
fuse F93 and soldered connection S335
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC5: CHECK FUSE F16 (BJB)
1 Key in OFF position.
2 CHECK Fuse F16 (BJB).
3 Check fuse F16 (20 A)
• Is the fuse OK?
→ Yes
GO to AC6
→ No
INSTALL a new fuse F16 (20 A). If the fuse
blows again, LOCATE and RECTIFY the
short circuit with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
AC6: CHECK THE VOLTAGE SUPPLY TO FUSE F16
1 Connect Fuse F16 (BJB).
2 Key in ON position.
3 Measure the voltage between fuse F16 (20 A)
and ground.
• Is battery voltage displayed?
→ Yes
GO to AC7
→ No
REPAIR circuit 15S-LE16A (GN/OG) be-
tween the headlamp relay and fuse F16
(BJB) with the aid of the Wiring Diagrams.
CHECK the operation of the system.

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417-01-172 Exterior Lighting 417-01-172

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AC7: CHECK CIRCUIT 15S-LE16 (GN/OG)
1 Measure the voltage between the left-hand
headlamp, connector C1146, pin 14, circuit
15S-LE16 (GN/OG), wiring harness side and
ground.

• Is battery voltage displayed?

→ Yes
GO to AC8
→ No
REPAIR circuit 15S-LE16 (GN/OG) between
fuse F16 and the headlamp with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
AC8: CHECK CIRCUIT 31-LE31 (BK)
1 Key in OFF position.
2 Measure the resistance between the left-hand
headlamp, connector C1146, pin 11, circuit 31-
LE31 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to AC9
→ No
REPAIR circuit 31-LE31 (BK) between the
headlamp and soldered connection S315
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC9: CHECK CIRCUIT 7-XL9 (YE/VT) (PRIOR TO 10/2001) OR 7-LE54 (YE/BK) (FROM 10/2001)
1 Connect Left-hand headlamp C1146.
2 Connect CJB C509.

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417-01-173 Exterior Lighting 417-01-173

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect Rear headlamp levelling sensor
C94.
4 Key in ON position.
5 Measure the voltage between the rear head-
lamp levelling sensor, connector C94, pin 3,
circuit 7-XL9 (YE/VT) (prior to 10/2001) or 7-
LE54 (YE/BK) (from 10/2001), wiring harness
side and ground.

• Is a voltage of 5 V displayed?
→ Yes
GO to AC10
→ No
REPAIR circuit 7-XL9 (YE/VT) (prior to
10/2001) or 7-LE54 (YE/BK) (from 10/2001)
between the headlamp and the headlamp
levelling sensor with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
AC10: CHECK CIRCUIT 8-XL9 (WH/VT) (PRIOR TO 10/2001) OR 8-LE54 (WH/BK) (FROM 10/2001)
1 Key in ON position.
2 Measure the voltage between the rear head-
lamp levelling sensor, connector C94, pin 2,
circuit 8-XL9 (WH/VT) (prior to 10/2001) or 8-
LE54 (WH/BK) (from 10/2001), wiring harness
side and ground.

• Is battery voltage displayed?

→ Yes

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417-01-174 Exterior Lighting 417-01-174

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the short to battery
voltage in circuit 8-XL9 (WH/VT) (prior to
10/2001) or 8-LE54 (WH/BK) (from 10/2001)
between the headlamp and the headlamp
levelling sensor with the aid of the Wiring
Diagrams, and CHECK and RENEW the
left-hand headlamp as necessary. CHECK
the operation of the system.
→ No
GO to AC11
AC11: CHECK CIRCUIT 8-XL9 (WH/VT) (PRIOR TO 10/2001) OR 8-LE54 (WH/BK) (FROM 10/2001)
1 Key in OFF position.
2 Measure the resistance between the rear
headlamp levelling sensor, connector C94, pin
2, circuit 8-XL9 (WH/VT) (prior to 10/2001) or
8-LE54 (WH/BK) (from 10/2001), wiring har-
ness side and ground.

• Is a resistance of more than 10 kOhms regis-

tered?
→ Yes
GO to AC12
→ No
LOCATE and RECTIFY the short to ground
in circuit 8-XL9 (WH/VT) (prior to 10/2001)
or 8-LE54 (WH/BK) (from 10/2001) between
the headlamp and the headlamp levelling
sensor with the aid of the Wiring Diagrams,
and CHECK and RENEW the left-hand
headlamp as necessary. CHECK the op-
eration of the system.
AC12: CHECK CIRCUIT 7-XL9A (YE/VT) (PRIOR TO 10/2001) OR 7-LE53 (YE/BU) (FROM
10/2001)
1 Key in OFF position.
2 Disconnect Front headlamp levelling sensor
C195.
3 Key in ON position.

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417-01-175 Exterior Lighting 417-01-175

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the front head-
lamp levelling sensor, connector C195, pin 3,
circuit 7-XL9A (YE/VT) (prior to 10/2001) or 7-
LE53 (YE/BU) (from 10/2001), wiring harness
side and ground.

• Is a voltage of 5 V displayed?
→ Yes
GO to AC13
→ No
REPAIR circuit 7-XL9A (YE/VT) (prior to
10/2001) or 7-LE53 (YE/BU) (from 10/2001)
between the headlamp and the headlamp
levelling sensor with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
AC13: CHECK CIRCUIT 8-XL9A (WH/VT) (PRIOR TO 10/2001) OR 8-LE53 (WH/BU) (FROM
10/2001)
1 Key in ON position.
2 Measure the voltage between the front head-
lamp levelling sensor, connector C195, pin 2,
circuit 8-XL9A (WH/VT) (prior to 10/2001) or 8-
LE53 (WH/BU) (from 10/2001), wiring harness
side and ground.

• Is battery voltage displayed ?

→ Yes
LOCATE and RECTIFY the short to battery
voltage in circuit 8-XL9A (WH/VT) (prior to
10/2001) or 8-LE53 (WH/BU) (from
10/2001) between the headlamp and the
headlamp levelling sensor with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
→ No
GO to AC14

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417-01-176 Exterior Lighting 417-01-176

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AC14: CHECK CIRCUIT 8-XL9A (WH/VT) (PRIOR TO 10/2001) OR 8-LE53 (WH/BU) (FROM
10/2001)
1 Key in OFF position.
2 Measure the resistance between the front
headlamp levelling sensor, connector C195,
pin 2, circuit 8-XL9A (WH/VT) (prior to
10/2001) or 8-LE53 (WH/BU) (from 10/2001),
wiring harness side and ground.

• Is a resistance of more than 10 kOhms regis-

tered?
→ Yes
GO to AC15
→ No
LOCATE and RECTIFY the short to ground
in circuit 8-XL9A (WH/VT) (prior to 10/2001)
or 8-LE53 (WH/BU) (from 10/2001) between
the headlamp and the headlamp levelling
sensor with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC15: CHECK CIRCUIT 8-XL9 (WH/VT) (PRIOR TO 10/2001) OR 8-LE54 (WH/BK) (FROM 10/2001)
1 Key in OFF position.
2 Disconnect Left-hand headlamp C1146.
3 Measure the resistance between the left-hand
headlamp, connector C1146, pin 10, circuit 8-
XL9 (WH/VT) (prior to 10/2001) or 8-LE54
(WH/BK) (from 10/2001), wiring harness side
and the rear headlamp levelling sensor, con-
nector C94, pin 2, circuit 8-XL9 (WH/VT) (prior
to 10/2001) or 8-LE54 (WH/BK) (from
10/2001), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to AC16
→ No

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417-01-177 Exterior Lighting 417-01-177

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 8-XL9 (WH/VT) (prior to
10/2001) or 8-LE54 (WH/BK) (from
10/2001) between the headlamp and the
headlamp levelling sensor with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
AC16: CHECK CIRCUIT 9-XL9 (BN/WH) (PRIOR TO 10/2001) OR 9-LE54 (BN/YE) (FROM 10/2001)
1 Measure the resistance between the left-hand
headlamp, connector C1146, pin 13, circuit 9-
XL9 (BN/WH) (prior to 10/2001) or 9-LE54
(BN/YE) (from 10/2001), wiring harness side
and the rear headlamp levelling sensor, con-
nector C94, pin 1, circuit 9-XL9 (BN/WH) (prior
to 10/2001) or 9-LE54 (BN/YE) (from 10/2001),
wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to AC17
→ No
REPAIR circuit 9-XL9 (BN/WH) (prior to
10/2001) or 9-LE54 (BN/YE) (from 10/2001)
between the headlamp and the headlamp
levelling sensor with the aid of the Wiring
Diagrams. CHECK the operation of the
system.
AC17: CHECK CIRCUIT 8-XL9A (WH/VT) (PRIOR TO 10/2001) OR 8-LE53 (WH/BU) (FROM
10/2001)
1 Measure the resistance between the left-hand
headlamp, connector C1146, pin 12, circuit 8-
XL9A (WH/VT) (prior to 10/2001) or 8-LE53
(WH/BU) (from 10/2001), wiring harness side
and the front headlamp levelling sensor, con-
nector C195, pin 2, circuit 8-XL9A (WH/VT)
(prior to 10/2001) or 8-LE53 (WH/BU) (from
10/2001), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to AC18
→ No

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417-01-178 Exterior Lighting 417-01-178

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 8-XL9A (WH/VT) (prior to
10/2001) or 8-LE53 (WH/BU) (from
10/2001) between the headlamp and the
headlamp levelling sensor with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
AC18: CHECK CIRCUIT 9-XL9A (BN/WH) (PRIOR TO 10/2001) OR 9-LE53 (BN/BU) (FROM
10/2001)
1 Measure the resistance between the left-hand
headlamp, connector C1146, pin 13, circuit 9-
XL9 (BN/WH) (prior to 10/2001) or 9-LE54
(BN/YE) (from 10/2001), wiring harness side
and the front headlamp levelling sensor, con-
nector C195, pin 1, circuit 9-XL9A (BN/WH)
(prior to 10/2001) or 9-LE53 (BN/BU) (from
10/2001), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
RENEW the front headlamp levelling sen-
sor. CHECK the operation of the system.
If the concern persists, RENEW the rear
headlamp levelling sensor. CHECK the
operation of the system.
→ No
REPAIR circuit 9-XL9A (BN/WH) (prior to
10/2001) or 9-LE53 (BN/BU) (from
10/2001) between the headlamp and the
headlamp levelling sensor with the aid of
the Wiring Diagrams. CHECK the opera-
tion of the system.
AC19: CHECK CIRCUIT 15-LE2A (GN/BU)
1 Key in OFF position.
2 Disconnect Left-hand headlamp C1146.
3 Key in ON position.
4 Switch on the dipped beam.

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417-01-179 Exterior Lighting 417-01-179

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between the left-hand
headlamp, connector C1146, pin 5, circuit 15-
LE2A (GN/BU), wiring harness side and
ground.

• Is battery voltage displayed?

→ Yes
GO to AC20
→ No
REPAIR circuit 15-LE2A (GN/BU) between
soldered connection S335 and the head-
lamp with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC20: CHECK CIRCUIT 31-LE31 (BK)
1 Key in OFF position.
2 Measure the resistance between the left-hand
headlamp, connector C1146, pin 11, circuit 31-
LE31 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to AC21
→ No
REPAIR circuit 31-LE31 (BK) between the
headlamp and soldered connection S315
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC21: CHECK LEFT-HAND HEADLAMP LEVELLING MOTOR
1 Remove the left-hand headlamp.
2 Disconnect Left-hand headlamp levelling mo-
tor.

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417-01-180 Exterior Lighting 417-01-180

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance at the left-hand head-
lamp between connector C1146, pin 5, circuit
(BU), component side and the headlamp level-
ling motor, circuit (BU), wiring harness side.

4 Measure the resistance at the left-hand head-

lamp between connector C1146, pin 11, circuit
(BK), component side and the headlamp level-
ling motor, circuit (BK), wiring harness side.

5 Measure the resistance at the left-hand head-

lamp between connector C1146, pin 14, circuit
(VT/YE), component side and the headlamp
levelling motor, circuit (VT/YE), wiring harness
side.

• Is the resistance in all three measurements

less than 2 ohms?
→ Yes
CHECK and if necessary RENEW the left-
hand headlamp levelling motor. CHECK
the operation of the system.
If the concern persists, CHECK and if nec-
essary RENEW the left-hand headlamp.
CHECK the operation of the system.
→ No

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417-01-181 Exterior Lighting 417-01-181

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the affected circuit between the
headlamp levelling motor and the headlamp
with the aid of the Wiring Diagrams.
CHECK the operation of the system.

AC22: CHECK CIRCUIT 15-LE2B (GN/BU)

1 Key in OFF position.
2 Disconnect Right-hand headlamp C1147.
3 Key in ON position.
4 Switch on the dipped beam.
5 Measure the voltage between the right-hand
headlamp, connector C1147, pin 5, circuit 15-
LE2B (GN/BU), wiring harness side and
ground.

• Is battery voltage displayed?

→ Yes
GO to AC23
→ No
REPAIR circuit 15-LE2B (GN/BU) between
soldered connection S335 and the head-
lamp with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC23: CHECK FUSE F18 (BJB)
1 Key in OFF position.
2 CHECK Fuse F18 (BJB).
3 Check fuse F18 (20 A)
• Is the fuse OK?
→ Yes
GO to AC24
→ No
INSTALL a new fuse F18 (20 A). If the fuse
blows again, LOCATE and RECTIFY the
short circuit with the aid of the Wiring Dia-
grams. CHECK the operation of the sys-
tem.
AC24: CHECK THE VOLTAGE SUPPLY TO FUSE F18
1 Connect Fuse F18 (BJB).
2 Key in ON position.
3 Measure the voltage between fuse F18 (20A)
(BJB) and ground.

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417-01-182 Exterior Lighting 417-01-182

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage displayed?

→ Yes
GO to AC25
→ No
REPAIR the voltage supply to fuse F18 with
the aid of the Wiring Diagrams. If the con-
cern is still not resolved CHECK and if nec-
essary RENEW the BJB. CHECK the op-
eration of the system.
AC25: CHECK CIRCUIT 15S-LE23 (GN/WH)
1 Measure the voltage between the right-hand
headlamp, connector C1147, pin 14, circuit
15S-LE23 (GN/WH), wiring harness side and
ground.

• Is battery voltage displayed?

→ Yes
GO to AC26
→ No
REPAIR circuit 15S-LE23 (GN/WH) be-
tween the BJB and the headlamp with the
aid of the Wiring Diagrams. CHECK the
operation of the system.
AC26: CHECK CIRCUIT 31-LE30 (BK)
1 Key in OFF position.
2 Measure the resistance between Right-hand
headlamp, connector C1147, pin 11, circuit31-
LE30 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to AC27

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417-01-183 Exterior Lighting 417-01-183

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR circuit 31-LE30 (BK) between the
headlamp and soldered connection S317
with the aid of the Wiring Diagrams.
CHECK the operation of the system.
AC27: CHECK RIGHT-HAND HEADLAMP LEVELLING MOTOR
1 Remove the right-hand headlamp.
2 Disconnect Right-hand headlamp levelling mo-
tor.
3 Measure the resistance at the right-hand head-
lamp between connector C1147, pin 5, circuit
(BU), component side and the headlamp level-
ling motor, circuit (BU), wiring harness side.

4 Measure the resistance at the right-hand head-

lamp between connector C1147, pin 11, circuit
(BK), component side and the headlamp level-
ling motor, circuit (BK), wiring harness side.

5 Measure the resistance at the right-hand head-

lamp between connector C1147, pin 14, circuit
(VT/YE), component side and the headlamp
levelling motor, circuit (VT/YE), wiring harness
side.

• Is the resistance in all three measurements

less than 2 ohms?

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417-01-184 Exterior Lighting 417-01-184

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
CHECK and if necessary RENEW the right-
hand headlamp levelling motor. CHECK
the operation of the system. If the concern
persists, CHECK and if necessary REPAIR
control circuit 8-LE46 (WH/RD) between
the headlamps. CHECK the operation of
the system.
→ No
REPAIR the affected circuit between the
headlamp levelling motor and the headlamp
with the aid of the Wiring Diagrams. If the
concern persists CHECK the system with
the aid of WDS.

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417-01-185 Exterior Lighting 417-01-185

GENERAL PROCEDURES

Headlamp Adjustment — Vehicles With: High Intensity Discharge Headlamps

GENERAL PROCEDURES

(32 113 0)

Vehicles with load-levelling shock absorbers

5. NOTE: Turn on the ignition key to position ""2”,
1. Leave the vehicle for at least a minute
to adjust the headlamp levelling according the
without shaking or loading it before
vehicle load.
headlamp adjustment.
NOTE: After replacing the left-hand headlamp
All vehicles
assembly (Master), the system has to be
2. Place the vehicle on a level surface and
initialized with WDS before the headlamp
make sure that the tire pressures are to
adjustment.
specification and that the vehicle is not
abnormally laden. NOTE: Switch on the low beam.
3. Set the measuring screen of the beam Adjust the headlamp so that the boundary
setting equipment to the following line touches the horizontal line.
headlamp adjustment value (X): X = 10
cm/10 m = 0 degrees, 34 minutes = 1.0%.
4. Alignment screws for the headlamp
adjustment.
1. Vertical alignment screw.
2. Horizontal alignment screw.

6. NOTE: Some scattered light from the low

beam may lie above the 15 degrees line.
NOTE: Readjustment of the vertical axis may be
necessary following adjustment of the horizontal
axis.
Adjust the headlamp so that the rising line
of the boundary line lies at the intersection
of horizontal line and the 15 degrees line
(left-hand drive vehicle shown).

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417-01-186 Exterior Lighting 417-01-186

GENERAL PROCEDURES

Headlamp Adjustment (32 113 0)

7. NOTE: Some scattered light from the low
beam may lie above the 15 degrees line.
General Equipment NOTE: Readjustment of the vertical axis may be
necessary following adjustment of the horizontal
Beam setting equipment axis.
Vehicles with load-levelling shock absorbers Adjust the headlamp so that the rising line
1. Leave the vehicle for at least a minute of the boundary line lies at the intersection
without shaking or loading it before of horizontal line and the 15 degree line
headlamp adjustment. (left-hand drive vehicle shown).
All vehicles
2. Place the vehicle on a level surface.
3. Make sure that the tire pressures are to
specification and that the vehicle is not
abnormally laden.
4. Operate the headlamp levelling system
several times and then set the headlamp
levelling switch to position 0.
5. Set the measuring screen of the beam
setting equipment to the correct headlamp
adjustment setting.
6. NOTE: Switch on the low beam.
Adjust the headlamp so that the boundary
line touches the horizontal line.

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417-01-187 Exterior Lighting 417-01-187

GENERAL PROCEDURES

Front Fog Lamp Adjustment

6. Adjust the front fog lamp so that the
boundary line touches the horizontal line.
General Equipment
Beam setting equipment
1. Remove the front fog lamp bezel.

7. Install the front fog lamp bezel.

2. Place the vehicle on a level surface.

3. Make sure that the tire pressures are to
specification and that the vehicle is not
abnormally laden.
4. Set the measuring screen of the beam
setting equipment to the correct front fog
lamp adjustment setting.
5. Adjust the front fog lamp alignment screw.

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417-01-188 Exterior Lighting 417-01-188

GENERAL PROCEDURES

Headlamp Masking — Vehicles With: High Intensity Discharge Headlamps

1. Remove the headlamp assemblies. For

4. Install the headlamp assembly rear cover.
additional information, refer to Headlamp
Assembly in this section. 1. Push down the locking tab.
2. Detach the headlamp assembly rear cover. 2. Install the retaining screws.
1. Remove the retaining screws.
2. Pull up the locking tab.

5. Install the headlamp assemblies. For

additional information, refer to Headlamp
Assembly in this section.
3. Turn the alignment lever.
1. Normal position ""0”
2. Travel position ""T”

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417-01-189 Exterior Lighting 417-01-189

REMOVAL AND INSTALLATION

Headlamp Bulb — Vehicles With: High Intensity Discharge Headlamps (32 147 0)
REMOVAL AND INSTALLATION

Removal
4. WARNING: Always wear safety glasses
1. Remove the headlamp assembly. For and protective gloves when removing
additional information, refer to Headlamp and installing Xenon headlamp bulbs.
Assembly in this section. Failure to follow these instructions
may result in personal injury.
2. Detach the headlamp assembly rear cover.
1. Remove the retaining screws. CAUTION: Do not touch the glass surface
2. Pull the locking tab. of the headlamp bulb.
Remove the headlamp bulb.

3. WARNING: High voltages are present

in this system. Ensure that the
headlamp assembly electrical Installation
connector is disconnected if the
headlamp assembly is removed. 1. To install, reverse the removal procedure.
CAUTION: Ensure that the headlamps are
not turned on with the headlamp bulb
electrical connector is disconnected.
Disconnect the headlamp bulb electrical
connector.

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417-01-190 Exterior Lighting 417-01-190

REMOVAL AND INSTALLATION

Headlamp Assembly (32 115 0)

Removal
1. Remove the radiator grille.

2. Remove the headlamp assembly.

1. Remove the headlamp assembly retainers.
2. Pull out the headlamp assembly.
• Disconnect the headlamp assembly electri-
cal connector.

Installation
1. NOTE: Clean the headlamp lens with a damp
cloth to avoid any electrostatic charging which
attracts dust to the plastic lens.
To install, reverse the removal procedure.
2. Adjust the headlamps. For additional
information, refer to Headlamp Adjustment
in this section.

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417-01-191 Exterior Lighting 417-01-191

REMOVAL AND INSTALLATION

Headlamp Leveling Sensor — Vehicles With: High Intensity Discharge Headlamps

Removal 4. Remove the headlamp levelling sensor

(rear sensor shown).
1. Raise and support the vehicle. For
additional information, refer to Section
100-02.
2. Disconnect the headlamp levelling sensor
electrical connector (rear sensor shown).

Installation
1. NOTE: After installing the headlamp levelling
3. Disconnect the connecting rod (rear sen- sensor the headlamp levelling system has to
sor shown). be intialized with WDS.
To install, reverse the removal procedure.

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417-02-1 Interior Lighting 417-02-1

SECTION 417-02 Interior Lighting

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Interior Lighting.................................................................................................................. 417-02-2

Inspection and Verification ............................................................................................... 417-02-2

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417-02-2 Interior Lighting 417-02-2

DIAGNOSIS AND TESTING

Interior Lighting
DIAGNOSIS AND TESTING

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical
damage.

Visual Inspection Chart

Electrical
– Fuse(s)
– Bulb(s)
– Switch(es)
– Wiring harness
– Electrical connector(s)
– Generic electronic module (GEM)
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

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418-00-1 Module Communications Network 418-00-1

SECTION 418-00 Module Communications Network

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DIAGNOSIS AND TESTING

Communications Network.................................................................................................. 418-00-2

Diagnosis and Testing ...................................................................................................... 418-00-2
Symptom Chart ................................................................................................................ 418-00-2
Pinpoint Tests .................................................................................................................. 418-00-3

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418-00-2 Module Communications Network 418-00-2

DIAGNOSIS AND TESTING

Communications Network
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 418-00 for Electrical

schematic and connector information. Fuse(s)
Wiring harness
Electrical connector(s).
Diagnosis and Testing
3. If an obvious cause for an observed or
1. CHECK the concern. reported concern is found, correct the cause
2. Visually inspect for obvious signs of (if possible) before proceeding to the next
mechanical or electricaldamage. step. CHECK the operation of the system.
4. If the concern is still present after the visual
Visual Inspection Chart — inspection has been carried out, REFER to
the Symptom Chart and PROCEED in
accordance with the fault symptom.
Symptom Chart

Condition Possible Sources Action

• Powertrain control module • Fuse(s) • CARRY OUT a fault diagnosis
(PCM) not communicating with • Circuit(s). with WDS.
the diagnostic unit • Powertrain control module
(PCM)
• ABS control module or elec- • Fuse(s) • CARRY OUT a fault diagnosis
tronic stability program module • Circuit(s). with WDS.
(ESP) not communicating with • ABS control module or elec-
the diagnostic unit tronic stability program (ESP)
module
• Restraint control module (RCM) • Fuse(s) • CARRY OUT a fault diagnosis
not communicating with the di- • Circuit(s). with WDS.
agnostic unit • Restraint control module (RCM)
• Generic electronic module • Fuse(s) • GO to Pinpoint Test A
(GEM) not communicating with • Circuit(s).
the diagnostic unit • Generic electronic module
(GEM)
• Instrument cluster not communi- • Fuse(s) • GO to Pinpoint Test B
cating with the diagnostic unit • Circuit(s).
• Instrument cluster.
• Heating and air conditioning • Fuse(s) • GO to Pinpoint Test C
control module or EATC module • Circuit(s).
not communicating with the di- • Heating and air conditioning
agnostic unit control module or EATC module
• Fuel-fired additional heater not • Fuse(s) • GO to Pinpoint Test D
communicating with the diag- • Circuit(s).
nostic unit • Fuel-fired additional heater
• Audio/navigation control unit • Fuse(s) • GO to Pinpoint Test E
VNR 9000 not communicating • Circuit(s).
with the diagnostic unit • Audio/navigation control unit
VNR 9000

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418-00-3 Module Communications Network 418-00-3

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Xenon headlamp(s) not com- • Fuse(s) • GO to Pinpoint Test F
municating with the diagnostic • Circuit(s).
unit • Xenon headlamp(s)
• Faulty communications between • Circuit(s). • GO to Pinpoint Test G
the modules (CAN bus) • Instrument cluster
• Heating and air conditioning
control module or EATC module
• Powertrain control module
(PCM)
• ABS control module or
electronic stability program
(ESP) module
NOTE: Vehicles with DuraTorq -
DI engine only:
• Injection pump
NOTE: Vehicles with ESP only:
• Steering shaft rotational angle
sensor
• Yaw rate sensor

Pinpoint Tests
PINPOINT TEST A: GENERIC ELECTRONIC MODULE (GEM) NOT COMMUNICATING WITH THE
DIAGNOSTIC UNIT
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FUSE F24
1 Key in OFF position.
2 CHECK Fuse F24 (BJB).
• Is the fuse OK?
→ Yes
GO to A2
→ No
RENEW fuse F24 (20 A). CHECK the sys-
tem again. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
A2: MEASURE THE VOLTAGE AT FUSE F24
1 Connect Fuse F24 (BJB).
2 Measure the voltage between fuse F24 (20 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to A3
→ No
REPAIR the voltage supply to fuse F24 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
A3: CHECK FUSE F25
1 CHECK Fuse F25 (BJB).

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418-00-4 Module Communications Network 418-00-4

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the fuse OK?

→ Yes
GO to A4
→ No
RENEW fuse F25 (15 A). CHECK the sys-
tem again. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
A4: MEASURE THE VOLTAGE AT FUSE F25
1 Connect Fuse F25 (BJB).
2 Measure the voltage between fuse F25 (15 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to A5
→ No
REPAIR the voltage supply to fuse F25 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
A5: CHECK THE VOLTAGE AT THE GEM
1 Disconnect GEM C426.
2 Measure the voltage between the GEM, con-
nector C426, pin 1, circuit 29-AA17 (OG/WH),
wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to A6
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F24 and the GEM with the
aid of the Wiring Diagrams. CHECK the op-
eration of the system.

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418-00-5 Module Communications Network 418-00-5

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A6: CHECK THE VOLTAGE AT THE GEM
1 Measure the voltage between the GEM, con-
nector C426, pin 5, circuit 29-LG25 (OG/BU),
wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to A7
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F25 and the GEM with the
aid of the Wiring Diagrams. CHECK the op-
eration of the system.
A7: CHECK THE CONTROL VOLTAGE AT THE GEM
1 Connect GEM C426.
2 Disconnect GEM C429.
3 Key in ON position.
4 Measure the voltage between the GEM, con-
nector C429, pin 12, circuit 8-AA30 (WH), wir-
ing harness side and ground.

• Is a voltage of at least 10 Volts measured?

→ Yes
GO to A8
→ No
LOCATE and RECTIFY the break in circuit
8-AA30 (WH) between the instrument clus-
ter and the GEM with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A8: CHECK THE GROUND CONNECTION OF THE GEM
1 Key in OFF position.
2 Disconnect GEM C427.
3 Measure the resistance between the GEM,
connector C427, pin 5, circuit 31-DK20 (BK),
wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to A9
→ No
LOCATE and RECTIFY the break in circuit
31-DK20 (BK) between the GEM and
ground connection G205 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
A9: CHECK THE GROUND CONNECTION OF THE GEM
1 Measure the resistance between the GEM,
connector C429, pin 1, circuit 91-DK20
(BK/RD), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to A10
→ No
LOCATE and RECTIFY the break in circuit
91-DK20 (BK/RD) between the GEM and
ground connection G203 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.

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418-00-7 Module Communications Network 418-00-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A10: CHECK THE CIRCUIT BETWEEN THE GEM AND THE DLC FOR OPEN CIRCUIT
1 Measure the resistance between the GEM,
connector C429, pin 16, circuit 8-EE9
(WH/GN), wiring harness side and the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes
LOCATE and RECTIFY the break in circuit
8-EE9 (WH/GN) or 8-EE10 (WH/BK) be-
tween the GEM and the DLC with the aid of
the Wiring Diagrams. CHECK the operation
of the system.
→ No
GO to A11
A11: CHECK THE CIRCUIT BETWEEN THE GEM AND THE DLC FOR A SHORT TO VOLTAGE
SUPPLY

WARNING: After disconnecting the battery wait at least 1 minute before disconnecting any
connectors from the safety restraint system to prevent the risk of accidental deployment.
Failure to observe this instruction can lead to injuries.

WARNING: To prevent the risk of accidental deployment, do not connect a radio keycode
saver when working on the safety restraint system. Failure to observe this instruction can
lead to injuries.
NOTE: The number of modules connected to the ISO 9141 bus depends on the equipment levels of
the vehicle. As a result, not every vehicle is equipped with all of the following modules.
1 Disconnect Ground cable at the battery.
2 Disconnect Heating and air conditioning control
module or EATC module C539b.
3 Disconnect Instrument cluster C449.
4 Disconnect Restraint control module (RCM)
C490.
5 Disconnect ABS control module or electronic
stability program (ESP) module C103.
6 Disconnect Fuel-fired additional heater C252.
7 Disconnect Xenon headlamp, left-hand side
C1146.
8 Disconnect Xenon headlamp, right-hand side
C1147.
9 Disconnect Audio/navigation control unit VNR
9000 C485.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
10 Connect Ground cable at the battery.
11 Key in ON position.
12 Measure the voltage between the DLC, con-
nector C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side and ground.

• Is a voltage measured?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to soldered
connection S178 with the aid of the Wiring
Diagrams. CHECK the system again.
→ No
GO to A12
A12: CHECK THE CIRCUIT BETWEEN THE GEM AND THE DLC FOR A SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side and ground.

• Is a resistance of less than 10 kOhm meas-

ured?
→ Yes
LOCATE and RECTIFY the short to ground
in the circuits connected to soldered con-
nection S178 with the aid of the Wiring Dia-
grams. CHECK the system again.
→ No
TEST the GEM and RENEW as necessary.
CHECK the operation of the system.

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418-00-9 Module Communications Network 418-00-9

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: INSTRUMENT CLUSTER NOT COMMUNICATING WITH THE DIAGNOSTIC

UNIT
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK FUSE F75
1 Key in OFF position.
2 CHECK Fuse F75 (CJB).
• Is the fuse OK?
→ Yes
GO to B2
→ No
RENEW fuse F75 (7.5 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
B2: MEASURE THE VOLTAGE AT FUSE F75
1 Connect Fuse F75 (CJB).
2 Measure the voltage between fuse F75 (7.5 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to B3
→ No
REPAIR the voltage supply to fuse F75 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
B3: CHECK FUSE F78.
1 CHECK Fuse F78 (CJB).
• Is the fuse OK?
→ Yes
GO to B4
→ No
RENEW fuse F78 (7.5 A). CHECK the sys-
tem again. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
B4: MEASURE THE VOLTAGE AT FUSE F78
1 Connect Fuse F78 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F78 (7.5 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to B5
→ No
REPAIR the voltage supply to fuse F78 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B5: CHECK THE VOLTAGE AT THE INSTRUMENT CLUSTER
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Measure the voltage between the instrument
cluster, connector C449, pin 1, circuit 29-GG14
(OG), wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to B6
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F75 and the instrument
cluster with the aid of the Wiring Diagrams.
CHECK the operation of the system.
B6: CHECK THE CONTROL VOLTAGE AT THE INSTRUMENT CLUSTER
1 Key in ON position.
2 Measure the voltage between the instrument
cluster, connector C449, pin 2, circuit 15-GG14
(GN/RD), wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to B7
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F78 and the instrument
cluster with the aid of the Wiring Diagrams.
CHECK the operation of the system.
B7: CHECK THE GROUND CONNECTION OF THE INSTRUMENT CLUSTER
1 Key in OFF position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the instru-
ment cluster, connector C449, pin 17, circuit
91-GG14 (BK/OG), wiring harness side and
ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to B8
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the instrument cluster and
ground connection G203 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
B8: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR OPEN
CIRCUIT
1 Measure the resistance between the instru-
ment cluster, connector C449, pin 30, circuit 8-
EE12 (WH), wiring harness side and the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes
LOCATE and RECTIFY the break in circuit
8-EE12 (WH) or 8-EE10 (WH/BK) between
the instrument cluster and the DLC with the
aid of the Wiring Diagrams. CHECK the op-
eration of the system.
→ No
GO to B9

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B9: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR A
SHORT TO VOLTAGE SUPPLY

WARNING: After disconnecting the battery wait at least 1 minute before disconnecting any
connectors from the safety restraint system to prevent the risk of accidental deployment.
Failure to observe this instruction can lead to injuries.

WARNING: To prevent the risk of accidental deployment, do not connect a radio keycode
saver when working on the safety restraint system. Failure to observe this instruction can
lead to injuries.
NOTE: The number of modules connected to the ISO 9141 bus depends on the equipment levels of
the vehicle. As a result, not every vehicle is equipped with all of the following modules.
1 Disconnect Ground cable at the battery.
2 Disconnect Heating and air conditioning control
module or EATC module C539b.
3 Disconnect Generic electronic module (GEM)
C429.
4 Disconnect Restraint control module (RCM)
C490.
5 Disconnect ABS control module or electronic
stability program (ESP) module C103.
6 Disconnect Fuel-fired additional heater C252.
7 Disconnect Xenon headlamp, left-hand side
C1146.
8 Disconnect Xenon headlamp, right-hand side
C1147.
9 Disconnect Audio/navigation control unit VNR
9000 C485.
10 Connect Ground cable at the battery.
11 Key in ON position.
12 Measure the voltage between the DLC, con-
nector C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side and ground.

• Is a voltage measured?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to soldered
connection S178 with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.
→ No

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418-00-13 Module Communications Network 418-00-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to B10
B10: CHECK THE CIRCUIT BETWEEN THE INSTRUMENT CLUSTER AND THE DLC FOR A
SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side and ground.

• Is a resistance of less than 10 kOhm meas-

ured?
→ Yes
LOCATE and RECTIFY the short to ground
in the circuits connected to soldered con-
nection S178 with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
→ No
CHECK and if necessary RENEW the in-
strument cluster. CHECK the operation of
the system.
PINPOINT TEST C: HEATING AND AIR CONDITIONING CONTROL MODULE OR EATC MODULE
NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK FUSE F65.
1 Key in OFF position.
2 CHECK Fuse F65 (CJB).
• Is the fuse OK?
→ Yes
GO to C2
→ No
RENEW fuse F65 (7.5 A). CHECK the sys-
tem again. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
C2: MEASURE THE VOLTAGE AT FUSE F65
1 Connect Fuse F65 (CJB).
2 Measure the voltage between fuse F65 (7.5 A)
and ground.
• Does the meter display battery voltage?
→ Yes

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to C3
→ No
REPAIR the voltage supply to fuse F65 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
C3: CHECK FUSE F76.
1 CHECK Fuse F76 (CJB).
• Is the fuse OK?
→ Yes
GO to C4
→ No
RENEW fuse F76 (7.5 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
C4: MEASURE THE VOLTAGE AT FUSE F76
1 Connect Fuse F76 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F76 (7.5 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to C13
→ No
GO to C5
C5: CHECK FUSE F6
1 Key in OFF position.
2 CHECK Fuse F6 (BJB).
• Is the fuse OK?
→ Yes
GO to C6
→ No
RENEW fuse F6 (40 A). CHECK the opera-
tion of the system. If the fuse blows again,
LOCATE and RECTIFY the short to ground
with the aid of the Wiring Diagrams.
C6: MEASURE THE VOLTAGE AT FUSE F6
1 Connect Fuse F6 (BJB).
2 Measure the voltage between fuse F6 (40 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to C7
→ No
REPAIR the voltage supply to fuse F6 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.

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418-00-15 Module Communications Network 418-00-15

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C7: CHECK FUSE F93.
1 CHECK Fuse F93 (CJB).
• Is the fuse OK?
→ Yes
GO to C8
→ No
RENEW fuse F93 (10 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
C8: MEASURE THE VOLTAGE AT FUSE F93
1 Connect Fuse F93 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F93 (10 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to C9
→ No
REPAIR the voltage supply to fuse F93 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
C9: CHECK THE VOLTAGE AT THE HEATER BLOWER RELAY
1 Key in OFF position.
2 Disconnect Heater blower relay C920.
3 Measure the voltage between the heater
blower relay, socket C920, pin 5, wiring har-
ness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to C10
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F6 and the heater blower
relay with the aid of the Wiring Diagrams.
CHECK the operation of the system.
C10: CHECK THE CONTROL VOLTAGE AT THE HEATER BLOWER RELAY
1 Key in ON position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the heater
blower relay, socket C920, pin 2, wiring har-
ness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to C11
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F93 and the heater
blower relay with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
C11: CHECK THE GROUND CONNECTION OF THE HEATER BLOWER RELAY
1 Key in OFF position.
2 Measure the resistance between the heater
blower relay, socket C920, pin 1, wiring har-
ness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to C12
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the heater blower relay and
ground connection G200 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.

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418-00-17 Module Communications Network 418-00-17

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C12: CHECK THE CENTRAL JUNCTION BOX
1 Measure the resistance between the heater
blower relay, socket C920, pin 3, wiring har-
ness side and fuse F76.

• Is a resistance of less than 2 Ohm measured?

→ Yes
RENEW the heater blower relay. CHECK
the operation of the system.
→ No
CHECK and if necessary RENEW the cen-
tral junction box. CHECK the operation of
the system.
C13: CHECK THE VOLTAGE AT THE HEATING AND AIR CONDITIONING CONTROL MODULE
OR THE EATC MODULE
1 Key in OFF position.
2 Disconnect Heating and air conditioning control
module or EATC module C539b.
3 Measure the voltage between the EATC mod-
ule or the heating and air conditioning control
module, connector C539b, pin 1, circuit 29-
FA43 (OG/WH), wiring harness side and
ground.

• Does the meter display battery voltage?

→ Yes
GO to C14
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F65 and the heating and
air conditioning control module or the EATC
module with the aid of the Wiring Diagrams.
CHECK the operation of the system.

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418-00-18 Module Communications Network 418-00-18

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C14: CHECK THE CONTROL VOLTAGE AT THE HEATING AND AIR CONDITIONING CONTROL
MODULE OR THE EATC MODULE
1 Key in ON position.
2 Measure the voltage between the EATC mod-
ule or the heating and air conditioning control
module, connector C539b, pin 14, circuit 15S-
FA43 (GN/WH), wiring harness side and
ground.

• Does the meter display battery voltage?

→ Yes
GO to C15
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F76 and the heating and
air conditioning control module or the EATC
module with the aid of the Wiring Diagrams.
CHECK the operation of the system.
C15: CHECK THE GROUND CONNECTION OF THE HEATING AND AIR CONDITIONING
CONTROL MODULE OR THE EATC MODULE
1 Key in OFF position.
2 Measure the resistance between the EATC
module or the heating and air conditioning con-
trol module, connector C539b, pin 15, circuit
31-FA43 (BK), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to C16
→ No

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418-00-19 Module Communications Network 418-00-19

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the break in the cir-
cuit between the heating and air condition-
ing control module or the EATC module and
ground connection G204 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
C16: CHECK THE CIRCUIT BETWEEN THE HEATING AND AIR CONDITIONING CONTROL
MODULE OR THE EATC MODULE AND THE DLC FOR OPEN CIRCUIT
1 Measure the resistance between the heating
and air conditioning control module or the
EATC module, connector C539b, pin 8, circuit
8-FA43 (WH/VT), wiring harness side and the
DLC, connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes
LOCATE and RECTIFY the break in circuit
8-FA43 (WH/VT) or 8-EE10 (WH/BK) be-
tween the heating and air conditioning con-
trol module or the EATC module and the
DLC with the aid of the Wiring Diagrams.
CHECK the operation of the system.
→ No
GO to C17
C17: CHECK THE CIRCUIT BETWEEN THE HEATING AND AIR CONDITIONING CONTROL
MODULE OR THE EATC MODULE AND THE DLC FOR A SHORT TO VOLTAGE SUPPLY

WARNING: After disconnecting the battery wait at least 1 minute before disconnecting any
connectors from the safety restraint system to prevent the risk of accidental deployment.
Failure to observe this instruction can lead to injuries.

WARNING: To prevent the risk of accidental deployment, do not connect a radio keycode
saver when working on the safety restraint system. Failure to observe this instruction can
lead to injuries.
NOTE: The number of modules connected to the ISO 9141 bus depends on the equipment levels of
the vehicle. As a result, not every vehicle is equipped with all of the following modules.
1 Disconnect Ground cable at the battery.
2 Disconnect Instrument cluster C449.
3 Disconnect Generic electronic module (GEM)
C429.
4 Disconnect Restraint control module (RCM)
C490.
5 Disconnect ABS control module or electronic
stability program (ESP) module C103.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
6 Disconnect Fuel-fired additional heater C252.
7 Disconnect Xenon headlamp, left-hand side
C1146.
8 Disconnect Xenon headlamp, right-hand side
C1147.
9 Disconnect Audio/navigation control unit VNR
9000 C485.
10 Connect Ground cable at the battery.
11 Key in ON position.
12 Measure the voltage between the DLC, con-
nector C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side and ground.

• Is a voltage measured?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to soldered
connection S178 with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.
→ No
GO to C18
C18: CHECK THE CIRCUIT BETWEEN THE HEATING AND AIR CONDITIONING CONTROL
MODULE OR THE EATC MODULE AND THE DLC FOR A SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side and ground.

• Is a resistance of less than 10 kOhm meas-

ured?
→ Yes

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418-00-21 Module Communications Network 418-00-21

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the short to ground
in the circuits connected to soldered con-
nection S178 with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
→ No
CHECK and if necessary RENEW the EATC
module or the heating and air conditioning
control module. CHECK the operation of the
system.
PINPOINT TEST D: FUEL-FIRED ADDITIONAL HEATER NOT COMMUNICATING WITH THE
DIAGNOSTIC UNIT
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK FUSE F23
1 Key in OFF position.
2 CHECK Fuse F23 (BJB).
• Is the fuse OK?
→ Yes
GO to D2
→ No
RENEW fuse F23 (15 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
D2: TEST THE VOLTAGE AT FUSE F23
1 Connect Fuse F23 (BJB).
2 Measure the voltage between fuse F23 (15 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to D3
→ No
REPAIR the voltage supply to fuse F23 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
D3: CHECK FUSE F82.
1 CHECK Fuse F82 (CJB).
• Is the fuse OK?
→ Yes
GO to D4
→ No
RENEW fuse F82 (7.5 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
D4: MEASURE THE VOLTAGE AT FUSE F82
1 Connect Fuse F82 (CJB).
2 Key in ON position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between fuse F82 (7.5 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to D5
→ No
REPAIR the voltage supply to fuse F82 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
D5: CHECK THE VOLTAGE AT THE ADDITIONAL HEATER
1 Key in OFF position.
2 Disconnect Additional heater C252.
3 Measure the voltage between the additional
heater, connector C252, pin 1, circuit 30-HA20
(RD), wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to D6
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the additional heater and fuse
F23 with the aid of the Wiring Diagrams.
CHECK the operation of the system.
D6: CHECK THE CONTROL VOLTAGE AT THE ADDITIONAL HEATER
1 Key in ON position.
2 Measure the voltage between the additional
heater, connector C252, pin 4, circuit 15-HA20
(GN/WH), wiring harness side and ground.

• Does the meter display battery voltage?

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418-00-23 Module Communications Network 418-00-23

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to D7
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the additional heater and fuse
F82 with the aid of the Wiring Diagrams.
CHECK the operation of the system.
D7: CHECK THE GROUND CONNECTION OF THE ADDITIONAL HEATER
1 Key in OFF position.
2 Measure the resistance between the additional
heater, connector C252, pin 2, circuit 31-HA20
(BK), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to D8
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the additional heater and
ground connection G104 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
D8: CHECK THE CIRCUIT BETWEEN THE ADDITIONAL HEATER AND THE DLC FOR OPEN
CIRCUIT
1 Measure the resistance between the additional
heater, connector C252, pin 3, circuit 8-EE11
(WH/VT), wiring harness side and the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes

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418-00-24 Module Communications Network 418-00-24

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the break in circuit
8-EE11 (WH/VT) or 8-EE10 (WH/BK) be-
tween the additional heater and the DLC
with the aid of the Wiring Diagrams. CHECK
the operation of the system.
→ No
GO to D9
D9: CHECK THE CIRCUIT BETWEEN THE ADDITIONAL HEATER AND THE DLC FOR A SHORT
TO VOLTAGE SUPPLY

WARNING: After disconnecting the battery wait at least 1 minute before disconnecting any
connectors from the safety restraint system to prevent the risk of accidental deployment.
Failure to observe this instruction can lead to injuries.

WARNING: To prevent the risk of accidental deployment, do not connect a radio keycode
saver when working on the safety restraint system. Failure to observe this instruction can
lead to injuries.
NOTE: The number of modules connected to the ISO 9141 bus depends on the equipment levels of
the vehicle. As a result, not every vehicle is equipped with all of the following modules.
1 Disconnect Ground cable at the battery.
2 Disconnect Instrument cluster C449.
3 Disconnect Generic electronic module (GEM)
C429.
4 Disconnect Restraint control module (RCM)
C490.
5 Disconnect ABS control module or electronic
stability program (ESP) module C103.
6 Disconnect Heating and air conditioning control
module or EATC module C539b.
7 Disconnect Xenon headlamp, left-hand side
C1146.
8 Disconnect Xenon headlamp, right-hand side
C1147.
9 Disconnect Audio/navigation control unit VNR
9000 C485.
10 Connect Ground cable at the battery.
11 Key in ON position.
12 Measure the voltage between the DLC, con-
nector C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side and ground.

• Is a voltage measured?

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to soldered
connection S178 with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.
→ No
GO to D10
D10: CHECK THE CIRCUIT BETWEEN THE ADDITIONAL HEATER AND THE DLC FOR A SHORT
TO GROUND
1 Key in OFF position.
2 Measure the resistance between the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side and ground.

• Is a resistance of less than 10 kOhm meas-

ured?
→ Yes
LOCATE and RECTIFY the short to ground
in the circuits connected to soldered con-
nection S178 with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
→ No
CHECK and if necessary RENEW the addi-
tional heater. CHECK the operation of the
system.
PINPOINT TEST E: AUDIO/NAVIGATION CONTROL UNIT VNR 9000 NOT COMMUNICATING
WITH THE DIAGNOSTIC UNIT
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK FUSE F72
1 Key in OFF position.
2 CHECK Fuse F72 (CJB).
• Is the fuse OK?
→ Yes
GO to E2
→ No
RENEW fuse F72 (20 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.

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418-00-26 Module Communications Network 418-00-26

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
E2: MEASURE THE VOLTAGE AT FUSE F72
1 Connect Fuse F72 (CJB).
2 Measure the voltage between fuse F72 (20 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to E3
→ No
REPAIR the voltage supply to fuse F72 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
E3: CHECK FUSE F69.
1 CHECK Fuse F69 (CJB).
• Is the fuse OK?
→ Yes
GO to E4
→ No
RENEW fuse F69 (7.5 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
E4: MEASURE THE VOLTAGE AT FUSE F69
1 Connect Fuse F69 (CJB).
2 Key in ACCESSORY position.
3 Measure the voltage between fuse F69 (7.5 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to E5
→ No
REPAIR the voltage supply to fuse F69 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
E5: CHECK THE VOLTAGE AT AUDIO/NAVIGATION CONTROL UNIT VNR 9000
1 Key in OFF position.
2 Disconnect Audio/navigation control unit C489
(vehicles with audio/navigation system built up
to 09/2001: C483).

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418-00-27 Module Communications Network 418-00-27

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the au-
dio/navigation control unit, connector C489
(vehicles with audio/navigation system built up
to 09/2001: C483), pin 1, circuit 29-MD15A
(OG/BK), wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to E6
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F72 and the au-
dio/navigation control unit with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
E6: CHECK THE VOLTAGE AT AUDIO/NAVIGATION CONTROL UNIT VNR 9000
1 Key in ACCESSORY position.
2 Measure the voltage between the au-
dio/navigation control unit, connector C489
(vehicles with audio/navigation system built up
to 09/2001: C483), pin 3, circuit 75-MD15
(YE/GN), wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to E7
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F69 and the au-
dio/navigation control unit with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
E7: CHECK THE GROUND CONNECTION OF AUDIO/NAVIGATION CONTROL UNIT VNR 9000
1 Key in OFF position.

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418-00-28 Module Communications Network 418-00-28

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the au-
dio/navigation control unit, connector C489
(vehicles with audio/navigation system built up
to 09/2001: C483), pin 2, circuit 91-MD34
(BK/YE), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to E8
→ No
LOCATE and RECTIFY the open circuit in
circuit 91-MD34 (BK/YE) between ground
connection G201 and the audio/navigation
control unit with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
E8: CHECK THE GROUND CONNECTION OF AUDIO/NAVIGATION CONTROL UNIT VNR 9000
1 Measure the resistance between the au-
dio/navigation control unit, connector C489
(vehicles with audio/navigation system built up
to 09/2001: C483), pin 6, circuit 91-MD15
(BK/GN), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to E9
→ No
LOCATE and RECTIFY the break in circuit
91-MD15 (BK/GN) or 91-MD15A (BK/GN)
between ground connection G201 and the
audio/navigation control unit with the aid of
the Wiring Diagrams. CHECK the operation
of the system.
E9: CHECK THE CIRCUIT BETWEEN AUDIO/NAVIGATION CONTROL UNIT VNR 9000 AND THE
DLC FOR OPEN CIRCUIT
1 Disconnect Audio/navigation control unit C485.

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418-00-29 Module Communications Network 418-00-29

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the au-
dio/navigation control unit, connector C485, pin
16, circuit 8-MD15 (WH/GN), wiring harness
side and the DLC, connector C418, pin 7, cir-
cuit 8-EE10 (WH/BK), wiring harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes
LOCATE and RECTIFY the break in circuit
8-MD15 (WH/GN) or 8-EE10 (WH/BK) be-
tween the audio/navigation control unit and
the DLC with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
→ No
GO to E10
E10: CHECK THE CIRCUIT BETWEEN AUDIO/NAVIGATION CONTROL UNIT VNR 9000 AND THE
DLC FOR A SHORT TO VOLTAGE SUPPLY

WARNING: After disconnecting the battery wait at least 1 minute before disconnecting any
connectors from the safety restraint system to prevent the risk of accidental deployment.
Failure to observe this instruction can lead to injuries.

WARNING: To prevent the risk of accidental deployment, do not connect a radio keycode
saver when working on the safety restraint system. Failure to observe this instruction can
lead to injuries.
NOTE: The number of modules connected to the ISO 9141 bus depends on the equipment levels of
the vehicle. As a result, not every vehicle is equipped with all of the following modules.
1 Disconnect Ground cable at the battery.
2 Disconnect Instrument cluster C449.
3 Disconnect Generic electronic module (GEM)
C429.
4 Disconnect Restraint control module (RCM)
C490.
5 Disconnect ABS control module or electronic
stability program (ESP) module C103.
6 Disconnect Heating and air conditioning control
module or EATC module C539b.
7 Disconnect Xenon headlamp, left-hand side
C1146.
8 Disconnect Xenon headlamp, right-hand side
C1147.
9 Disconnect Additional heater C252.
10 Connect Ground cable at the battery.
11 Key in ON position.

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418-00-30 Module Communications Network 418-00-30

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
12 Measure the voltage between the DLC, con-
nector C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side and ground.

• Is a voltage measured?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to soldered
connection S178 with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.
→ No
GO to E11
E11: CHECK THE CIRCUIT BETWEEN AUDIO/NAVIGATION CONTROL UNIT VNR 9000 AND THE
DLC FOR A SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the DLC,
connector C418, pin 7, circuit 8-EE10
(WH/BK), wiring harness side and ground.

• Is a resistance of less than 10 kOhm meas-

ured?
→ Yes
LOCATE and RECTIFY the short to ground
in the circuits connected to soldered con-
nection S178 with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
→ No
CHECK and if necessary RENEW the au-
dio/navigation control unit. CHECK the op-
eration of the system.

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418-00-31 Module Communications Network 418-00-31

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST F: XENON HEADLAMP(S) NOT COMMUNICATING WITH THE DIAGNOSTIC UNIT
CONDITIONS DETAILS/RESULTS/ACTIONS
F1: DETERMINE THE CONDITIONS UNDER WHICH THE FAULT OCCURS
1 Key in OFF position.
2 Connect the diagnostic tool.
3 Key in ON position.
4 Check the communications with the other Xe-
non headlamp.
• Is there a fault in the communications with both
of the Xenon headlamps?
→ Yes
GO to F2
→ No
Communications only faulty to the right-
hand Xenon headlamp. GO to F7
Communications only faulty to the left-hand
Xenon headlamp. GO to F10
F2: CHECK FUSE F93
1 Key in OFF position.
2 CHECK Fuse F93 (CJB).
• Is the fuse OK?
→ Yes
GO to F3
→ No
RENEW fuse F93 (10 A). CHECK the op-
eration of the system. If the fuse blows
again, LOCATE and RECTIFY the short to
ground with the aid of the Wiring Diagrams.
F3: MEASURE THE VOLTAGE AT FUSE F93
1 Connect Fuse F93 (CJB).
2 Key in ON position.
3 Measure the voltage between fuse F93 (10 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to F4
→ No
REPAIR the voltage supply to fuse F93 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
F4: CHECK THE VOLTAGE AT THE RIGHT-HAND XENON HEADLAMP

WARNING: High voltages are present in the system. Ensure that the headlamp connector is
disconnected before starting work on the headlamps. Failure to observe this instruction
can lead to injuries.
1 Key in OFF position.
2 Disconnect Xenon headlamp, right-hand side
C1147.
3 Key in ON position.

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418-00-32 Module Communications Network 418-00-32

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the right-hand
Xenon headlamp, connector C1147, pin 5, cir-
cuit 15-LE2B (GN/BU), wiring harness side and
ground.

• Does the meter display battery voltage?

→ Yes
GO to F5
→ No
LOCATE and RECTIFY the break in the cir-
cuit between fuse F93 and soldered connec-
tion S335 with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
F5: CHECK THE CIRCUIT BETWEEN THE DATA LINK CONNECTOR (DLC) AND THE RIGHT-
HAND XENON HEADLAMP FOR OPEN CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the right-hand
Xenon headlamp, connector C1147, pin 2, cir-
cuit 8-LE30 (WH/RD), wiring harness side and
the DLC, C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to F6
→ No
LOCATE and RECTIFY the break in circuit
8-EE1 (WH/RD) or 8-EE10 (WH/BK) be-
tween the DLC and soldered connection
S385 with the aid of the Wiring Diagrams.
CHECK the operation of the system.

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418-00-33 Module Communications Network 418-00-33

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
F6: CHECK THE CIRCUIT BETWEEN THE XENON HEADLAMP AND THE DLC FOR A SHORT TO
VOLTAGE SUPPLY

WARNING: After disconnecting the battery wait at least 1 minute before disconnecting any
connectors from the safety restraint system to prevent the risk of accidental deployment.
Failure to observe this instruction can lead to injuries.

WARNING: To prevent the risk of accidental deployment, do not connect a radio keycode
saver when working on the safety restraint system. Failure to observe this instruction can
lead to injuries.
NOTE: The number of modules connected to the ISO 9141 bus depends on the equipment levels of
the vehicle. As a result, not every vehicle is equipped with all of the following modules.
1 Disconnect Ground cable at the battery.
2 Disconnect Instrument cluster C449.
3 Disconnect Generic electronic module (GEM)
C429.
4 Disconnect Restraint control module (RCM)
C490.
5 Disconnect ABS control module or electronic
stability program (ESP) module C103.
6 Disconnect Heating and air conditioning control
module or EATC module C539b.
7 Disconnect Xenon headlamp, left-hand side
C1146.
8 Disconnect Audio/navigation control unit VNR
9000 C485.
9 Disconnect Additional heater C252.
10 Connect Ground cable at the battery.
11 Key in ON position.
12 Measure the voltage between the DLC, con-
nector C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side and ground.

• Is a voltage measured?
→ Yes
LOCATE and RECTIFY the short to voltage
supply in the circuits connected to soldered
connection S178 with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.
→ No

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418-00-34 Module Communications Network 418-00-34

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the short to ground
in the circuits connected to soldered con-
nection S178 with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
F7: CHECK THE VOLTAGE AT THE RIGHT-HAND XENON HEADLAMP

WARNING: High voltages are present in the system. Ensure that the headlamp connector is
disconnected before starting work on the headlamps. Failure to observe this instruction
can lead to injuries.
1 Key in OFF position.
2 Disconnect Xenon headlamp, right-hand side
C1147.
3 Key in ON position.
4 Measure the voltage between the right-hand
Xenon headlamp, connector C1147, pin 5, cir-
cuit 15-LE2B (GN/BU), wiring harness side and
ground.

• Does the meter display battery voltage?

→ Yes
GO to F8
→ No
LOCATE and RECTIFY the break in circuit
15-LE2B (GN/BU) between the right-hand
Xenon headlamp and soldered connection
S335 with the aid of the Wiring Diagrams.
CHECK the operation of the system.
F8: CHECK THE GROUND CONNECTION OF THE RIGHT-HAND XENON HEADLAMP
1 Key in OFF position.
2 Measure the resistance between the right-hand
Xenon headlamp, connector C1147, pin 11,
circuit 31-LE30 (BK), wiring harness side and
ground.

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418-00-35 Module Communications Network 418-00-35

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to F9
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the right-hand Xenon head-
lamp and ground connection G105 with the
aid of the Wiring Diagrams. CHECK the op-
eration of the system.
F9: CHECK THE CIRCUIT BETWEEN THE RIGHT-HAND XENON HEADLAMP AND THE DATA
LINK CONNECTOR (DLC) FOR OPEN CIRCUIT
1 Measure the resistance between the right-hand
Xenon headlamp, connector C1147, pin 2, cir-
cuit 8-LE30 (WH/RD), wiring harness side and
the DLC, C418, pin 7, circuit 8-EE10 (WH/BK),
wiring harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes
LOCATE and RECTIFY the break in circuit
8-LE30 (WH/RD) between the right-hand
Xenon headlamp and soldered connection
S385 with the aid of the Wiring Diagrams.
CHECK the operation of the system.
→ No
CHECK and if necessary RENEW the right-
hand Xenon headlamp. CHECK the opera-
tion of the system.
F10: CHECK THE VOLTAGE AT THE LEFT-HAND XENON HEADLAMP

WARNING: High voltages are present in the system. Ensure that the headlamp connector is
disconnected before starting work on the headlamps. Failure to observe this instruction
can lead to injuries.
1 Key in OFF position.
2 Disconnect Xenon headlamp, left-hand side
C1146.
3 Key in ON position.

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418-00-36 Module Communications Network 418-00-36

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the left-hand
Xenon headlamp, connector C1146, pin 5, cir-
cuit 15-LE2A (GN/BU), wiring harness side and
ground.

• Does the meter display battery voltage?

→ Yes
GO to F11
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the left-hand Xenon headlamp
and soldered connection S335 with the aid
of the Wiring Diagrams. CHECK the opera-
tion of the system.
F11: CHECK THE GROUND CONNECTION OF THE LEFT-HAND XENON HEADLAMP
1 Key in OFF position.
2 Measure the resistance between the left-hand
Xenon headlamp, connector C1146, pin 11,
circuit 31-LE31 (BK), wiring harness side and
ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to F12
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the left-hand Xenon headlamp
and ground connection G104 with the aid of
the Wiring Diagrams. CHECK the operation
of the system.

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418-00-37 Module Communications Network 418-00-37

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
F12: CHECK THE CIRCUIT BETWEEN THE LEFT-HAND XENON HEADLAMP AND THE DATA
LINK CONNECTOR (DLC) FOR OPEN CIRCUIT
1 Measure the resistance between the left-hand
Xenon headlamp, connector C1146, pin 2, cir-
cuit 8-LE31 (WH), wiring harness side and the
DLC, C418, pin 7, circuit 8-EE10 (WH/BK), wir-
ing harness side.

• Is a resistance of more than 2 Ohm measured?

→ Yes
LOCATE and RECTIFY the break in circuit
8-LE31 (WH) between the left-hand Xenon
headlamp and soldered connection S385
with the aid of the Wiring Diagrams. CHECK
the operation of the system.
→ No
CHECK and if necessary RENEW the left-
hand Xenon headlamp. CHECK the opera-
tion of the system.
PINPOINT TEST G: FAULTY COMMUNICATIONS BETWEEN THE MODULES (CAN BUS)
CONDITIONS DETAILS/RESULTS/ACTIONS
NOTE: The number of modules connected to the CAN bus depends on the equipment levels of the ve-
hicle. As a result, not every vehicle is equipped with all of the following modules.
G1: CHECK THE CAN BUS (+) FOR OPEN CIRCUIT
1 Key in OFF position.
2 Disconnect Instrument cluster C449.
3 Disconnect EATC module or heating and air
conditioning control module C539b.
4 Disconnect Powertrain control module (PCM)
C100.
5 Disconnect Injection pump C210.
6 Disconnect ABS control module or electronic
stability program (ESP) module C103.
7 Disconnect Steering shaft rotational angle sen-
sor C512.
8 Disconnect Yaw rate sensor C511.

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418-00-38 Module Communications Network 418-00-38

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
9 Measure the resistance between the data link
connector (DLC), connector C418, pin 6, circuit
4-EC1 (GY/RD), wiring harness side and the
instrument cluster, connector C449, pin 16, cir-
cuit 4-EC2 (GY/RD), wiring harness side.

10 Measure the resistance between the DLC,

connector C418, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539b, pin 9, circuit 4-EC8
(GY/VT), wiring harness side.

11 Measure the resistance between the DLC,

connector C418, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the PCM, connector
C100, pin 50, circuit 4-EC7 (GY/RD), wiring
harness side.

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418-00-39 Module Communications Network 418-00-39

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
NOTE: Vehicles with DuraTorq - DI engine only:
12 Measure the resistance between the DLC,
connector C418, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the injection pump,
connector C210, pin 2, circuit 4-EC6 (GY), wir-
ing harness side.

13 Measure the resistance between the DLC,

connector C418, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the ABS control mod-
ule or the electronic stability program module
(ESP), connector C103, pin 24, circuit 4-EC9
(GY), wiring harness side.

NOTE: Vehicles with ESP only:

14 Measure the resistance between the DLC,
connector C418, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the steering shaft rota-
tional angle sensor, connector C512, pin 3, cir-
cuit 4-EC11 (GY/OG), wiring harness side.

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418-00-40 Module Communications Network 418-00-40

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
NOTE: Vehicles with ESP only:
15 Measure the resistance between the DLC,
connector C418, pin 6, circuit 4-EC1 (GY/RD),
wiring harness side and the steering shaft rota-
tional angle sensor, connector C511, pin 3, cir-
cuit 4-EC12 (GY/RD), wiring harness side.

• Is a resistance of less than 2 Ohms measured

following all of the measurements?
→ Yes
GO to G2
→ No
LOCATE and RECTIFY the break in the af-
fected circuit with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
G2: CHECK THE CAN BUS (-) FOR OPEN CIRCUIT
1 Measure the resistance between the data link
connector (DLC), connector C418, pin 14, cir-
cuit 5-EC1 (BU/RD), wiring harness side and
the instrument cluster, connector C449, pin 32,
circuit 5-EC2 (BU/RD), wiring harness side.

2 Measure the resistance between the DLC,

connector C418, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the EATC module or
the heating and air conditioning control mod-
ule, connector C539b, pin 10, circuit 5-EC8
(BU/WH), wiring harness side.

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418-00-41 Module Communications Network 418-00-41

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the DLC,
connector C418, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the PCM, connector
C100, pin 49, circuit 5-EC7 (BU/RD), wiring
harness side.

NOTE: Vehicles with DuraTorq - DI engine only:

4 Measure the resistance between the DLC,
connector C418, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the injection pump,
connector C210, pin 1, circuit 5-EC6 (BU), wir-
ing harness side.

5 Measure the resistance between the DLC,

connector C418, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the ABS control mod-
ule or the electronic stability program module
(ESP), connector C103, pin 40, circuit 5-EC9
(BU), wiring harness side.

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418-00-42 Module Communications Network 418-00-42

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
NOTE: Vehicles with ESP only:
6 Measure the resistance between the DLC,
connector C418, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the steering shaft rota-
tional angle sensor, connector C512, pin 4, cir-
cuit 5-EC11 (BU/BK), wiring harness side.

NOTE: Vehicles with ESP only:

7 Measure the resistance between the DLC,
connector C418, pin 14, circuit 5-EC1 (BU/RD),
wiring harness side and the steering shaft rota-
tional angle sensor, connector C511, pin 2, cir-
cuit 5-EC12 (BU/RD), wiring harness side.

• Is a resistance of less than 2 Ohms measured

following all of the measurements?
→ Yes
GO to G3
→ No
LOCATE and RECTIFY the break in the af-
fected circuit with the aid of the Wiring Dia-
grams. CHECK the operation of the system.
G3: CHECK THE CAN BUS FOR A SHORT TO VOLTAGE SUPPLY
1 Key in ON position.
2 Measure the voltage between the DLC, con-
nector C418, pin 6, circuit 4-EC1 (GY/RD) and
ground.

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418-00-43 Module Communications Network 418-00-43

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the DLC, con-
nector C418, pin 14, circuit 5-EC1 (BU/RD)
and ground.

• Is a voltage measured?
→ Yes
LOCATE and RECTIFY the short to voltage
in the affected circuit with the aid of the Wir-
ing Diagrams. CHECK the operation of the
system.
→ No
GO to G4
G4: CHECK THE CAN BUS FOR A SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the DLC,
connector C418, pin 6, circuit 4-EC1 (GY/RD)
and ground.

3 Measure the resistance between the DLC,

connector C418, pin 14, circuit 5-EC1 (BU/RD)
and ground.

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418-00-44 Module Communications Network 418-00-44

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is a resistance greater than 10 kOhm meas-

ured in both cases?
→ Yes
CHECK and if necessary RENEW the af-
fected module with faulty communications.
CHECK the operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in the affected circuit with the aid of the Wir-
ing Diagrams. CHECK the operation of the
system.

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418-01-1 Module Configuration 418-01-1

SECTION 418-01 Module Configuration

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
GENERAL PROCEDURES

Module Configuration ........................................................................................................ 418-01-2

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418-01-2 Module Configuration 418-01-2

GENERAL PROCEDURES

Module Configuration
GENERAL PROCEDURES

1. In order to minimise module variations, 2. The following need(s) to be programmed

different equipment levels and following a replacement:
functionalities are incorporated in the
• Powertrain control module (PCM)
same module. Following a replacement
this module needs to be programmed or 3. The following need(s) to be configured
configured with the aid of WDS. All of the following a replacement:
required data (software) are loaded by the • Restraint control module (RCM)
WDS into the module. In the process it is • Generic electronic module (GEM)
for example also possible to replace older • Instrument cluster
software versions with a more current
version. If the required data are already 4. In order to adjust certain settings and
present in the module then it needs to be function values, various modules will need
configured. In this process certain to be initialised after the replacement or
parameters are set, and inputs and outputs after disconnecting the power supply.
are enabled or disabled. As a general rule, Here, the input signals received by a
these parameters should be read out with module are for example allocated to a
the aid of WDS from the module which is particular operating state. The initialisation
to be replaced and then transferred to the process takes place on a system-specific
new module. If this is not possible (e.g. basis. For further information REFER to
because the old module will no longer the relevant section. The following need(s)
react), then the vehicle-specific data will to be initialised following a replacement:
need to be entered manually via a • Passive anti-theft system (PATS)
selection list in WDS or via a code which • Injection pump
can be obtained from the Technical • Steering shaft rotational angle sensor (only
Hotline. REFER TO WDS for further on vehicles with ESP)
information.
• Sun roof module
• Xenon headlamps (headlamp levelling)
• Electric window lifter modules

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419-01-1 Anti-Theft - Passive 419-01-1

SECTION 419-01 Anti-Theft - Passive

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Anti-Theft - Passive ........................................................................................................... 419-01-2

DIAGNOSIS AND TESTING

Anti-Theft - Passive ........................................................................................................... 419-01-4

Principles of Operation ..................................................................................................... 419-01-4
Inspection and Verification ............................................................................................... 419-01-5
Symptom Chart ................................................................................................................ 419-01-6
Pinpoint Tests .................................................................................................................. 419-01-6

GENERAL PROCEDURES

Key Programming Using Two Programmed Keys ......................................... (33 005 0) 419-01-12
Key Programming Using Diagnostic Equipment ........................................... (33 005 0) 419-01-13
Key Programming Switch State Control............................................................................. 419-01-14
Anti-Theft Security Access............................................................................ (33 004 0) 419-01-15

REMOVAL AND INSTALLATION

Passive Anti-Theft System (PATS) Transceiver............................................ (33 662 0) 419-01-16

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419-01-2 Anti-Theft - Passive 419-01-2

DESCRIPTION AND OPERATION

Anti-Theft - Passive
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
3 - Starter relay
1 - Ignition key (with integral
transponder) 4 - Fuel injection pump control
unit - Vehicles with 2.0L die-
2 - Passive anti-theft system sel engine
(PATS) transceiver

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419-01-3 Anti-Theft - Passive 419-01-3

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
5 - PATS light emitting diode
(LED)
6 - Powertrain control module
(PCM)

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419-01-4 Anti-Theft - Passive 419-01-4

DIAGNOSIS AND TESTING

Anti-Theft - Passive
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 419-01 for

schematic and connector information.
PATS Control Function
The control functions are contained in the PCM.
Principles of Operation This module carries out all of the PATS functions,
such as receiving the identification code from the
encoded key and controlling engine enable. The
General
PCM initiates the encoded key interrogation
The passive anti-theft system (PATS) uses radio sequence when the vehicle ignition switch is
frequency identification technology and a unique turned to II or III. When the key is turned to the 0
encryption code to deter a drive away theft. position, the PCM will remain powered up for
Passive means that it does not require any approximately five seconds. This is the maximum
activity from the user. time allowed for the insertion of a second key to
initiate the customer key programming sequence.
Encoded Ignition Key
Transceiver Module
The PATS uses a specially encoded ignition key.
Each encoded ignition key contains a The transceiver module communicates with the
permanently installed electronic device called a PATS encoded ignition key. This module is
transponder. Each transponder contains a unique located behind the steering column lower shroud
electronic identification code which may be any and contains an antenna connected to a small
one of millions of combinations. Each encoded electronic module. During each vehicle start
ignition key must be programmed to the vehicle's sequence the transceiver module reads the
PATS control function within the powertrain encoded ignition key identification code and
control module (PCM) before it can be used to sends data to the PATS control function within
start the engine. There are special diagnostic the PCM. No re-initialization needs to occur with
repair procedures outlined in this manual that the removal or installation of a new PATS
must be carried out if an encoded ignition key transceiver.
needs to be changed.
The PATS transponder key is identified by a blue PATS Target Function - Vehicles with 2.0L diesel
insert. Previous PATS transponder keys that engine
have a red insert are not compatible with this
vehicle and must not be used. The fuel injection pump is equipped with a fuel
injection pump control module (PATS target
Only Ford approved ignition keys should be used function). The PATS control function within the
as some aftermarket encoded ignition keys not PCM communicates with the fuel injection pump
purchased from a Ford approved source may fail control module to enable or disable the engine
to operate especially at extreme temperatures. from starting. The fuel injection pump control
NOTE: If a non programmed key has been used, module must receive the correct enable
further key reading is inhibited for 20 seconds. sequence through the control area network
During this 20 seconds, no ignition key will start (CAN) from the PCM within one second after the
the engine. engine is started or the engine will be disabled.
A minimum of 2 encoded ignition keys must be The PATS control function and the fuel injection
programmed to a vehicle in order for the engine pump control module share security data when
to start. A maximum of 8 ignition keys may be first installed together that makes them a
programmed to a vehicle. The PATS control matched pair. This shared security data is stored
function within the PCM will enter Anti-Scan even if the vehicle battery has been
Mode if an attempt to start the vehicle with a non disconnected. Therefore after this security data
programmed ignition key (with the correct sharing, these modules will not function in other
mechanical cut) is made. vehicles unless they are reconfigured using
WDS.

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419-01-5 Anti-Theft - Passive 419-01-5

DIAGNOSIS AND TESTING (Continued)

Special diagnostic procedures must be carried key when the ignition switch is in position II. The
out using WDS if either the PCM or fuel injection PATS will be activated and will disable the
pump are changed. All elements of the PATS vehicle from starting if there is:
must be functional before the engine is allowed to
• A damaged encoded ignition key
start. If any of the components are not working
properly, the vehicle will not start and the anti- • An unprogrammed key
theft indicator will flash a fault code. • A non-encoded key (key has no electronics or
does not have a blue insert)
When the ignition key is turned to the II or III
position the PCM sends an encrypted code to the • Damaged wiring
fuel injection pump control unit. In turn the fuel • Damaged transceiver
injection pump control unit sends an encrypted • Damaged PCM
code back to the PCM to indicate that it has • Shielded ignition key
recognized the PCM. The PCM then sends a
signal back to the fuel injection pump control unit • A mismatch between PCM and fuel injection
to allow fuelling to commence. pump control module - Vehicles with 2.0L
diesel engine

Anti-Theft Indicator
The PATS system uses a visual anti-theft Inspection and Verification
indicator that is controlled by the PATS control 1. Verify the customer concern.
function. The indicator will self-test for three 2. Visually inspect for obvious signs of
seconds when the ignition switch is turned to II or mechanical or electrical damage.
III under normal operation. If there is a PATS
concern, the indicator will either flash rapidly or Visual Inspection Chart
glow steadily depending on the concern when the
ignition switch is turned to II or III and then it will Mechanical Electrical
flash a fault code 10 times. Refer to WDS and – Ignition lock cylinder – Fuse(s)
follow the on-screen instructions. The PATS – PATS key – Wiring harness
system also flashes the anti-theft indicator every – Use of an non- – Electrical
two seconds at ignition OFF to act as a visual encoded PATS key connector(s)
deterrent.
– More than one – Relay(s)
PATS key on key – PATS transceiver
J1850 Communication Network chain
– Ignition switch
The J1850 standard corporate protocol (SCP) – Use of an non-
– Transmission range
communications network is used for diagnostic programmed PATS
sensor - Vehicles
purposes only. The CAN Bus is utilized to send key
with automatic
and receive messages between the PATS control transaxle
function and the fuel injection pump control
– PCM
module.
– Fuel injection pump
control module -
Starter Relay Vehicles with 2.0L
The starter relay is also used as an additional diesel engine
means of disabling the vehicle engine. The 3. If an obvious cause for an observed or
starter relay ground connection is disabled when reported concern is found, correct the cause
PATS cannot read an encoded or non encoded (if possible) before proceeding to the next
ignition key at ignition position II. However, the step.
system will not store a DTC or flash the anti-theft 4. If the cause is not visually evident, verify the
indicator if a valid ignition key is read but a fault symptom and use WDS to diagnose the
occurs in the starter relay circuit. REFER to system in conjunction with the following
Section 303-06. The relay is enabled when PATS Flash Code Index, Symptom Chart and
control function reads a valid encoded ignition Pinpoint tests.

Flash Code Index

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419-01-6 Anti-Theft - Passive 419-01-6

DIAGNOSIS AND TESTING

Indicator
Flash
Code Description/Condition Possible Source Action
11 PATS transceiver signal is not received Transceiver wiring GO to Pinpoint
transceiver connector, Test A.
transceiver or PCM
12 Transceiver antenna coil concern, Vehicle Transceiver Install a new
does not start transceiver
13 Non-PATS key or damaged encoded igni- PATS encoded ignition REFER to WDS
tion key, or no key code received. Vehicle key PATS test. Follow
does not start the instructions
13 Transponder programming concern, Crypto Ignition key REFER to WDS
transponder only. Vehicle does not start PATS test. Follow
the instructions
14 Partial key read of PATS key. Vehicle does PATS encoded ignition REFER to WDS
not start key. Transceiver PATS test. Follow
the instructions
15 Incorrect key code, Unprogrammed PATS PATS encoded ignition REFER to WDS
key (keycode format OK). Vehicle does not key PATS test. Follow
start (20 second anti-scan invoked) the instructions
16 CAN communication link between the PCM Circuit, Fuel injection REFER to WDS
and Fuel injection pump control module pump control module or PATS test. Follow
(diesel only). Vehicle does not start PCM the instructions
21 Number of programmed PATS encoded Incorrect number of keys REFER to WDS
keys below minimum. Vehicle does not start programmed or PATS PATS test. Follow
encoded ignition key the instructions
22 NVM Configuration failure. No security ID New PCM or new fuel REFER to WDS
exchange between PCM and Fuel injection injection pump control PATS test. Follow
pump control module (diesel only). Vehicle module the instructions
does not start
23 Data mismatch (received data does not New PCM or new fuel REFER to WDS
match what was expected) Security mes- injection pump control PATS test. Follow
sages do not match between PCM and Fuel module the instructions
injection pump control module. Vehicle does
not start
Symptom Chart

Condition Possible Sources Action

• The anti-theft indicator is al- • Fuse. • Carry out WDS PATS test. Fol-
ways/never on - no anti-theft in- • Circuit. low the instructions.
dicator self-test • Anti-theft LED.
• PCM.
• The anti-theft system does not • Starter relay. • GO to Pinpoint Test B.
operate correctly - engine does • Circuit.
not crank • PCM.

Pinpoint Tests
PINPOINT TEST A: THE PATS TRANSCEIVER SIGNAL IS NOT RECEIVED
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE TRANSCEIVER POWER CIRCUIT - CIRCUIT 15-GL37 (GN/BK)
1 Key in OFF position.

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419-01-7 Anti-Theft - Passive 419-01-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect PATS Transceiver Module C479.
3 Key in ON position.
4 Measure the voltage between PATS trans-
ceiver module C479 pin 1, circuit 15-GL37
(GN/BK), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A2.
→ No
REPAIR circuit 15-GL37A (GN/BK). TEST
the system for normal operation.
A2: CHECK THE TRANSCEIVER GROUND CIRCUIT - CIRCUIT 91-GL37 (BK/GN)
1 Key in OFF position.
2 Measure the resistance between PATS trans-
ceiver module C479 pin 2, circuit 91-GL37
(BK/GN), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A3.
→ No
REPAIR circuit 91-GL37 (BK/GN). TEST the
system for normal operation.
A3: CHECK THE PATS TRANSCEIVER FOR VOLTAGE - CIRCUIT 8-GL37 (WH/GN)
1 Key in ON position.

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419-01-8 Anti-Theft - Passive 419-01-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the PATS trans-
ceiver C479 pin 4, circuit 8-GL37 (WH/GN),
harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A5.
→ No
GO to A4.
A4: CHECK CIRCUIT 8-GL37 (WH/GN) FOR OPEN
NOTE: When a new PCM is installed, the encoded ignition keys must be reprogrammed
1 Key in OFF position.
2 Disconnect PCM C100.
3 Measure the resistance between PATS trans-
ceiver C479 pin 4, circuit 8-GL37 (WH/GN),
harness side and PCM C100 Pin 53, harness
side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new PCM. REFER to Section
303-14. REPROGRAM the encoded ignition
keys. REFER to Key Programming Using
Diagnostic Equipment in this section. TEST
the system for normal operation.
→ No
REPAIR circuit 8-GL37 (WH/GN). TEST the
system for normal operation.
A5: CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR VOLTAGE - CIRCUIT 10-GL37
(GY/OG)
1 Connect PATS Transceiver Module C479.
2 Key in ON position.

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419-01-9 Anti-Theft - Passive 419-01-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage by carefully backprobing
between C12, pin 12, circuit 10-GL37
(GY/OG), and ground.

• Is the voltage greater than 8 volts?

→ Yes
GO to A7.
→ No
GO to A6.
A6: CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR OPEN - CIRCUIT 10-GL37 (GY/OG)
1 Disconnect In-line Connector C12.
2 Disconnect PATS Transceiver Module C479.
3 Measure the resistance between PATS trans-
ceiver C479 pin 3, circuit 10-GL37 (GY/OG),
harness side and C12 pin 12, harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new PATS transceiver. REFER
to Passive Anti-Theft System (PATS)
Transceiver in this section. TEST the sys-
tem for normal operation.
→ No
REPAIR circuit 10-GL37 (GY/OG). TEST
the system for normal operation.
A7: CHECK THE TRANSCEIVER RECEIVE CIRCUIT FOR OPEN - CIRCUIT 10-GL37 (GY/OG)
1 Key in OFF position.
2 Disconnect PCM C100.

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419-01-10 Anti-Theft - Passive 419-01-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between PCM C100
pin 19, circuit 10-GL37 (GY/OG), harness side
and C12 pin 12, harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new PCM. REFER to Section
303-14. REPROGRAM the encoded ignition
keys. REFER to Key Programming Using
Diagnostic Equipment in this section. TEST
the system for normal operation.
→ No
REPAIR circuit 10-GL37 (GY/OG). TEST
the system for normal operation.
PINPOINT TEST B: THE ANTI-THEFT SYSTEM DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE STARTING SYSTEM GROUND
1 Key in OFF position.
2 Disconnect Starter Relay C910.
3 Key in START position.
4 Measure the resistance between starter relay
pin 2, circuit 31S-BB12 (BK/YE), harness side
and ground while holding the key in position III.

• Is the resistance less than 5 ohms?

→ Yes
DIAGNOSE the starting system. REFER to
Section 303-06..
→ No
GO to B2.

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419-01-11 Anti-Theft - Passive 419-01-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B2: CHECK CIRCUIT 31S-BB12 (BK/YE) FOR OPEN
NOTE: When a new PCM is installed, the encoded ignition keys must be reprogrammed, TURN the
ignition switch to position 0 then position II. RETRIEVE DTCs. If PATS DTCs are present, GO to PCM
Diagnostic Trouble Code (DTC) Index. If no DTCs are retrieved, the PATS system is OK.
1 Key in OFF position.
2 Disconnect PCM C100.
3 Measure the resistance between PCM C100
pin 27 (use pin 32 on 60 pin PCM connector),
harness side and start relay C910 pin 2, circuit
31S-BB12 (BK/YE), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new PCM. REFER to Section
303-14. REPROGRAM the encoded ignition
keys. REFER to Key Programming Using
Diagnostic Equipment in this section. TEST
the system for normal operation.
→ No
REPAIR circuit 31S-BB12 (BK/YE). TEST
the system for normal operation.

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419-01-12 Anti-Theft - Passive 419-01-12

GENERAL PROCEDURES

Key Programming Using Two Programmed Keys (33 005 0)

GENERAL PROCEDURES

1. NOTE: This procedure only works if two or 5. Within ten seconds of turning the ignition
more programmed ignition keys are available lock cylinder to the OFF position, insert
and it is desired to program additional key(s). the unprogrammed ignition key (new key)
If two keys are not available. For additional into the lock cylinder and turn the lock
information, refer to Key Programming-Erase cylinder from the OFF position to the RUN
All Keys and Program Two Keys in this position (maintain the ignition lock
section. cylinder in the RUN position for less than 5
NOTE: The Spare Key Programming Switch is a seconds).
WDS/FDS 2000 programmable switch which 6. Check the new programmed key starts the
provides the capability to enable/disable the engine. Turn the ignition key to the OFF
normal customer Spare Key Programming position for five seconds then try to start
Procedure. If the Spare Key Programming Switch vehicle with the new programmed key.
is not enabled , refer to Security Access then 7. To programme additional key(s), repeat the
select Spare Key Programming Switch; Enabled. applicable key programming procedure
NOTE: If the programming procedure is not from step 1.
successful, the new key(s) will not start the
vehicle and the anti-theft indicator will flash. If the
programming procedure was not successful
leave the ignition switch in the RUN position for
at least 30 seconds, repeat the Key Programming
procedure from step 1. If the failure repeats, refer
to Diagnostic and testing to review DTCs an carry
out Pinpoint Tests.
NOTE: A maximum of eight ignition keys can be
programmed to a passive anti-theft system
(PATS) equipped vehicle.
NOTE: If the steps are not carried out as
outlined, the programming procedure will end.
NOTE: Ignition keys must have correct
mechanical key cut for the vehicle and must be a
PATS encoded key.
Insert the first programmed key into the
ignition lock cylinder and turn the lock
cylinder from the OFF position to the RUN
position (maintain ignition lock cylinder in
the RUN position for one second).
2. Turn ignition lock cylinder to the OFF
position and remove the first key from the
ignition lock cylinder.
3. Within five seconds of turning the ignition
lock cylinder to the OFF position, insert
the second programmed ignition key into
the ignition lock cylinder and turn the
ignition lock from the OFF position to the
RUN position (maintain the ignition lock
cylinder in the RUN position for one
second).
4. Turn the ignition lock cylinder to the OFF
position and remove the second key from
the lock cylinder.

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419-01-13 Anti-Theft - Passive 419-01-13

GENERAL PROCEDURES

Key Programming Using Diagnostic Equipment (33 005 0)

1. NOTE: This procedure is used when a

customer needs keys programmed into the
system and does not have two programmed
ignition keys available. This procedure is also
useful when programmed ignition key(s) have
been lost or when the ignition lock cylinder has
been replaced or when you are required to
erase a key(s) from the passive anti-theft
alarm system (PATS) memory.
NOTE: This procedure will erase all programmed
ignition keys from the vehicle memory and the
vehicle will not start until two keys have been
reprogrammed to the vehicle.
NOTE: Two PATS encoded keys with the correct
mechanical cut must be available to carry out this
procedure. One or both of them may be the
original keys.
NOTE: If the remaining keys are with the
customer and are not available with the vehicle,
then instruct the customer to refer to the Owner's
Manual under the Programming Spare PATS Key
Procedure, for instructions on programming the
remaining keys.
Turn the ignition lock cylinder from the
OFF position to the RUN position.
2. Using WDS/FDS 2000 select
Body/Security/PATS Functions from the
menu. Obtain security access. For
additional information, refer to Security
Access in this section.
3. Using WDS/FDS 2000 menu select Ignition
Key Code Erase.
4. Turn the ignition lock cylinder to the OFF
position and disconnect WDS/FDS 2000.
5. Insert the first encoded key into the
ignition lock cylinder and turn the lock
cylinder to the RUN position for three
seconds.
6. Remove the first encoded key from the
ignition lock cylinder.
7. Insert the second encoded key into the
ignition lock cylinder and turn the lock
cylinder to the RUN position for three
seconds.
8. Remove the second encoded key from the
ignition lock cylinder.
9. The vehicle should now start with both
ignition keys.

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419-01-14 Anti-Theft - Passive 419-01-14

GENERAL PROCEDURES

Key Programming Switch State Control

1. NOTE: The Spare Key Programming Switch is

a WDS/FDS 2000 programmable switch which
provides the capability to enable/disable the
normal customer Spare Key Programming
Procedure detailed in the owner's manual
(customer scan program a spare ignition key
by cycling two programmed ignition keys and
then cycling the new key). This programmable
switch is provided as a convenience for rental
company fleets or other fleet purchasers who
may not want the Spare Key Programming
procedure available to the vehicle driver.
NOTE: The default setting on delivery of all new
vehicles is ENABLE.
Insert a programmed ignition key into the
ignition lock cylinder and turn the lock
cylinder from the OFF position to the RUN
position.
2. Using WDS/FDS 2000 select
Body/Security/PATS Functions from the
menu.
3. Select Security Access. For additional
information, refer to Security Access in
this section.
4. Using WDS/FDS 2000 select Spare Key
Programming Switch from the menu.
Follow the on-screen directions.

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419-01-15 Anti-Theft - Passive 419-01-15

GENERAL PROCEDURES

Anti-Theft Security Access (33 004 0)

1. NOTE: This procedure is utilized to obtain

passive anti-theft system (PATS) security
access. PATS security access must be
granted to erase ignition key codes or
enable/disable the spare key programming
switch. This procedure invokes an inherent 10
minute time delay prior to granting security
access during which WDS/FDS 2000 must
remain connected to the vehicle. Once
security access has been granted, a security
access command menu is displayed which
offers various command options. For
additional information, refer to Powertrain
Control Module (PCM) Configuration
Command Index in this section.
NOTE: Once security access has been granted,
multiple security access commands should be
executed (if necessary) prior to exiting the
command menu. This avoids repeating the
procedure and thus avoids any additional 10
minute time delay.
Use WDS/FDS 2000 to obtain anti-theft
security access.
2. After the 10 minute security access
procedure has been completed, a new
menu will be displayed with command
options. Select the function as required
before exiting out of this menu. (do not
select more functions than the procedure
calls for). Once exited out of this menu, the
security access procedure must be carried
out again to carry out additional
commands.

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419-01-16 Anti-Theft - Passive 419-01-16

REMOVAL AND INSTALLATION

Passive Anti-Theft System (PATS) Transceiver (33 662 0)

REMOVAL AND INSTALLATION

Removal 4. Remove the audio control switch (if

equipped).
1. Disconnect the battery ground cable. For
additional information, refer to Section • Disconnect the electrical connector.
414-01.
2. Remove the instrument panel lower panel.
1. Remove the retaining screws.
2. Release the retaining clips.

5. Detach the steering column upper shroud

from the steering column lower shroud.
1. Using a thin bladed screwdriver, release
the two clips (one each side).
2. Detach the upper shroud.
3. Detach the audio control switch from the
steering column lower shroud (if
equipped).
• Using a thin bladed screwdriver, release
the locking tang.

6. Remove the steering column lower shroud.

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419-01-17 Anti-Theft - Passive 419-01-17

REMOVAL AND INSTALLATION (Continued)

7. Remove the PATS transceiver (steering

column shown removed for clarity).
• Disconnect the electrical connector.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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419-08-1 Cellular Phone 419-08-1

SECTION 419-08 Cellular Phone

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Cellular Phone................................................................................................................... 419-08-2

DIAGNOSIS AND TESTING

Cellular Phone................................................................................................................... 419-08-4

Inspection and Verification ............................................................................................... 419-08-4
Symptom Chart ................................................................................................................ 419-08-4
Pinpoint Test .................................................................................................................... 419-08-5

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419-08-2 Cellular Phone 419-08-2

DESCRIPTION AND OPERATION

Cellular Phone
DESCRIPTION AND OPERATION

Item Part Description

Item Part Description Number
Number
4 - Portable support electronics
1 - Cellular phone antenna (PSE) module
2 - Cellular phone microphone
3 - Cellular phone speaker

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419-08-3 Cellular Phone 419-08-3

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
1 - Cellular phone and handset
holder

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419-08-4 Cellular Phone 419-08-4

DIAGNOSIS AND TESTING

Cellular Phone
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 419-08 for Electrical

schematic and connector information. Handset holder
Cellular phone
Portable Support Electronics (PSE) Module
Inspection and Verification
3. Verify that the cellular phone operates
1. Verify the customers concern. correctly out of the vehicle before proceeding
2. Visually inspect for obvious signs of electrical to the next step.
damage. 4. Verify the audio unit or navigation system
display module is working correctly before
Visual Inspection Chart proceeding to the next step.
Electrical 5. If an obvious cause for an observed or
Fuse(s) reported concern is found, correct the cause
Wiring Harness (if possible) before proceeding to the next
Electrical connector(s) step.
Microphone 6. If the cause is not visually evident, verify the
Cellular phone antenna symptom and refer to the Symptom Chart.
Cellular phone speaker
Symptom Chart

Condition Possible Sources Action

• The handset battery does not • Circuit(s). • GO to Pinpoint Test A.
charge • Handset holder.
• Cellular phone.
• PSE Module.
• Interference from the cellular • Incorrect navigation system dis- • MAKE sure that MUTE is se-
phone speaker - vehicles with play module settings. lected in the navigation system
Traffic Pro navigation system display module RADIO MODE.
TEST the system for normal op-
eration.
• Reduced sound or no sound • Circuit(s). • GO to Pinpoint Test B.
through the speakers • Cellular phone speaker.
• Handset holder.
• PSE Module.
• No SVC display stays on • Cellular phone antenna. • GO to Pinpoint Test C.
• Handset holder.
• The hands-free system is inop- • Cellular phone and handset • CHECK the cellular phone is
erative holder electrical connectors. correctly installed into the hand-
set holder. TEST the system for
normal operation.
• Microphone sensitivity too low • Microphone incorrectly adjusted. • INCREASE the microphone
(user is difficult to hear when sensitivity on the PSE module
making calls) during a conversation.
• Microphone location incorrect. • CHECK the location of the mi-
crophone. INSTALL the micro-
phone in the correct location if
necessary.

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DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Microphone sensitivity too high • Microphone incorrectly adjusted. • DECREASE the microphone
(user hears their own voice sensitivity on the PSE module
when making calls) during a conversation.
• Whistling noise when the cellu- • Microphone incorrectly adjusted. • DECREASE the microphone
lar phone is in use sensitivity on the PSE module
during a conversation.
• The cellular phone speaker op- • Electrical connection to the • INSTALL a new PSE module
erates but the audio unit speak- navigation system display wiring harness. TEST the sys-
ers do not mute. module. tem for normal operation. If the
• Threshold voltage to the naviga- concern persists, INSTALL a
tion system display module is new PSE module. TEST the
not achieved. system for normal operation.
• Audio unit or navigation system • INSTALL a new audio unit.
display module. • INSTALL a new navigation sys-
tem display module.

Pinpoint Test
PINPOINT TEST A: THE HANDSET BATTERY DOES NOT CHARGE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE POWER SUPPLY TO THE PSE MODULE
1 Disconnect PSE Module C1002.
2 Key in ACCESSORY position.
3 Measure the voltage between the PSE module
C1002 pin 4, harness side and ground; and the
PSE module C1002 pin 5, harness side and
ground.

• Are the voltages greater than 10 volts?

→ Yes
GO to A3.
→ No
GO to A2.
A2: CHECK THE PSE MODULE WIRING HARNESS FOR OPEN
1 Disconnect PSE Module Wiring Harness.
2 Key in ACCESSORY position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the PSE
module C1002 pin 4, harness side and PSE
module wiring harness, pin 6, harness side;
and the PSE module C1002 pin 5, harness
side and PSE module wiring harness, pin 6,
harness side.

• Are the resistances less than 5 ohms?

→ Yes
GO to A3.
→ No
REPAIR the circuit. TEST the system for
normal operation.
A3: CHECK THE PSE MODULE FOR GROUND
1 Measure the resistance between the PSE
module C1002 pin 6, harness side and ground;
and the PSE module C1002 pin 3, harness
side and ground.

• Are the resistances less than 5 ohms?

→ Yes
CLEAN the handset holder and cellular
phone electrical connectors. TEST the sys-
tem for normal operation. If the concern
persists, INSTALL a new handset holder.
TEST the system for normal operation. If the
concern persists, INSTALL a new PSE
module.
→ No
INSTALL a new PSE module wiring har-
ness. TEST the system for normal opera-
tion.

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419-08-7 Cellular Phone 419-08-7

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: REDUCED SOUND OR NO SOUND THROUGH THE SPEAKERS

CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE CELLULAR PHONE SPEAKER
1 Disconnect Cellular Phone Speaker.
2 Measure the resistance between the speaker
terminals (component side).

• Is the resistance between 3 and 5 ohms?

→ Yes
REPAIR if necessary the circuit between the
cellular phone speaker and the PSE mod-
ule. TEST the system for normal operation.
If the concern persists, CLEAN the handset
holder and cellular phone electrical connec-
tors. TEST the system for normal operation.
INSTALL a new handset holder. TEST the
system for normal operation. If the concern
still persists, INSTALL a new PSE module.
TEST the system for normal operation.
→ No
INSTALL a new cellular phone speaker.
TEST the system for normal operation.
PINPOINT TEST C: NO SVC DISPLAY STAYS ON
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE HANDSET HOLDER ANTENNA CABLE FOR OPEN
1 Disconnect Handset Holder Antenna Cable.
2 Measure the resistance between the center pin
of the handset holder antenna connection and
the center pin of the antenna cable connector.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 1 ohm?

→ Yes
TEST the system for normal operation.
→ No
INSTALL a new handset holder. TEST the
system for normal operation.

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419-10-1 Multifunction Electronic Modules 419-10-1

SECTION 419-10 Multifunction Electronic Modules

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
DESCRIPTION AND OPERATION

Module Controlled Functions ............................................................................................. 419-10-2

DIAGNOSIS AND TESTING

Generic Electronic Module (GEM) ..................................................................................... 419-10-6

Description of operation.................................................................................................... 419-10-6
Diagnosis and Testing ...................................................................................................... 419-10-7
Symptom Chart ............................................................................................................... 419-10-7
Pinpoint Test .................................................................................................................... 419-10-7

REMOVAL AND INSTALLATION

Generic Electronic Module (GEM) ..................................................................................... 419-10-14

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419-10-2 Multifunction Electronic Modules 419-10-2

DESCRIPTION AND OPERATION

Module Controlled Functions

DESCRIPTION AND OPERATION

General
From 2001.25 MY a generic electronic module
(GEM) is used.
The module has the following functions:

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DESCRIPTION AND OPERATION (Continued)

– Direction indicator / hazard warning light The interior lights consist of the front and rear
control dome lamps and the position lamps in the interior
– Interior light control door trim panels.
– Dimmer control Direction Indicators / Hazard Warning Lights
– Heated windscreen and rear window control When the direction indicator control is actuated,
– Wiper interval control the direction indicator lamps on the relevant side
– Warning for lights switched on of the vehicle are activated with a frequency of
– Warning for door not closed 1.3 Hz (80 times per minute).
– PRNDL warning At the same time, a clicking sound is emitted via
– Generation of warning and confirmation tones the steering column switch and the direction
indicator telltale is activated.
– Battery protection function
– Closing system control In the event of a defective direction indicator
lamp, the flashing frequency is doubled.
– Checking that doors and tailgate are closed However, this does not apply to hazard warning
– Control of window regulators and sliding roof light mode.
within scope of overall closing function
Heated Windscreen
– Monitoring of static vehicle condition (anti-
theft warning system) The heated windscreen can be activated via the
ON / OFF switch after starting the engine.
For the European Area of Operations, two
different GEMs are fitted ex works. They differ The heated windscreen is deactivated:
only with regard to the anti-theft warning function. – Automatically after 4 minutes.
All other functions are available as standard in – By switching off the ignition.
both modules. – Via the ON / OFF switch.
Only the GEM with anti-theft warning function is – If the engine stalls.
available for servicing. This must be adapted to – If the charging system is defective.
the vehicle equipment level using the WDS
tester, as otherwise, the functions which are not The signal indicating whether or not the engine is
available in the vehicle are recognised as faults running, is transmitted to the GEM from the
and are stored in the memory. instrument cluster.
Control Functions Heated Rear Window

The GEM monitors the following functions: The heated rear window can be activated via the
ON / OFF switch after switching on the ignition.
Interior Lights
The heated rear window is deactivated:
The interior lights are activated, if:
– Automatically after 14 minutes.
– A vehicle door is opened and the ignition
– By switching off the ignition.
switch is in the OFF or ACC position.
– Via the ON / OFF switch.
– The ignition switch is turned from the ON or
Windscreen Wipers
START position to the ACC or OFF position.
– The vehicle is unlocked by means of the radio The GEM controls the windscreen washer
remote control. function and the wipe interval.
The interior lights are extinguished: If the windscreen washer function is actuated, the
activation of the windscreen wipers is delayed.
– 25 seconds after all doors were closed but Three wipes are then performed. An additional
the vehicle was not locked. wipe is performed after approx. 5 seconds.
– If the vehicle is locked.
The wipe interval is adjustable in 6 steps via the
– If the ignition switch is turned from the OFF or adjuster ring on the wiper lever.
ACC position to the ON or START position.
The other functions are independent of the GEM
Deactivation is effected via the dimming function and continue to be available in the event of
over a period of 1.7 seconds. failure of the GEM.

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DESCRIPTION AND OPERATION (Continued)

Rear Window Wiper In addition, all GEM warning signals are
deactivated after 30 minutes.
For simultaneously operated windscreen wipers
and rear window wiper as well as separately The timer is activated if the ignition switch is
activated rear window wiper, only the intermittent turned to the OFF or the ACC position.
wiping function is available for the rear window The timer is reset if:
wiper.
– The ignition switch is turned to the ON or the
Only the intermittent wiping function is available if START position.
reverse gear is engaged when the rear window
wiper is switched on. – A door is opened (including luggage
compartment lid or tailgate).
Rear Window Wiper Automatic Function – A lock is released.
If the windscreen wipers are switched on and Automatic Re-locking
reverse gear is engaged, the rear window wiper If the vehicle is unlocked via the radio remote
is automatically activated, if it is switched off. In control but no door is opened and the ignition is
this case, the mode is adapted to the windscreen not switched on within 45 seconds, the GEM
wiper mode. If the windscreen wipers are automatically re-locks the vehicle via central
operated in intermittent mode, the rear window locking. The anti-theft warning system is also
wiper is adapted to the currently selected interval activated in vehicles equipped with this system.
step. If the windscreen wipers are operated in
continuous wiping mode, the rear window wiper Overall Closing Function
also switches to continuous wiping mode. In The electrically-operated windows and the
contrast to the windscreen wipers, only one electrically-operated sun roof (if fitted) can also
wiping speed is available for the rear window be opened or closed when the ignition is
wiper. switched off, using the radio remote control.
For the washer function, the GEM activates the In order to open the electrically-operated
wipers without delay. windows and the electrically-operated sun roof (if
Warning Buzzer when Leaving the Vehicle with the fitted), the unlocking button on the radio remote
Lights Switched on control must be pressed for approx. 2 seconds.
With the ignition switched off and the lights The electrically-operated windows and the
switched on, a warning signal is emitted via the electrically-operated sun roof (if fitted) are then
GEM when a door is opened. fully opened automatically. Therefore, the button
can be released.
Door Open Warning
NOTE: The electrically-operated sun roof always
If a door is not closed and the ignition is switched opens in the sliding position, irrespective of the
on, a warning light illuminates in the instrument current position. If the electrically-operated sun
cluster. roof is in the raised position, it is first closed and
PRNDL Warning (Automatic Transmission) is then driven to the fully open position in sliding
mode.
If the automatic transmission selector lever is not
in the "P" position and the ignition is switched off, The opening movement is interrupted if one of
a warning signal sounds. the following conditions is fulfilled:
Trip Computer Entry Confirmation – The opening button on the radio remote
control is pressed again.
For each entry via the control switch of the trip
computer, the GEM emits a tone as entry – The closing button on the radio remote
confirmation control is pressed.
– The ignition is switched on.
Battery Protection Function
In order to close the electrically-operated
In order to prevent discharge of the battery due to windows and the electrically-operated sun roof (if
continuously-activated consumers, the interior fitted), the locking button on the radio remote
lights are switched off automatically after 10 control must be pressed for approx. 2 seconds.
minutes and all other interior lamps (interior
mirror, reading lamp, glove compartment, The electrically-operated windows and the
footwell) after 30 minutes. electrically-operated sun roof (if fitted) are then

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DESCRIPTION AND OPERATION (Continued)

fully closed automatically. Therefore, the button

can be released.
The closing movement is interrupted if one of the
following conditions is fulfilled:
– The opening button on the radio remote
control is pressed.
– The closing button on the radio remote
control is pressed again.
– The ignition is switched on.
– An object becomes trapped.
WARNING: Each window regulator must
be individually initialised after the battery
has been disconnected. If individual
window regulators are disconnected,
only these must be initialised.For
additional information, refer to Section
501-11.
NOTE: If an object has become trapped, the anti-
pinch protection is activated and the window is
driven back into a safe position.
Receiver Aerial for Radio Remote Control
The GEM aerial consists of a 1100 millimetre
long wire, which is located in the wiring harness
along the instrument panel carrier.
Anti-theft Warning System
The optional anti-theft warning system registers
unauthorised interference with the vehicle
visually and acoustically. If the vehicle is centrally
or double locked with the ignition switched off,
the anti-theft warning system is automatically
activated after 20 seconds.
If the anti-theft warning system is activated, the
following components are monitored:
– Vehicle doors
– Bonnet
– Luggage compartment lid or tailgate
– Radio
– Ignition
Electric Window Regulators
The global closing function is monitored by the
GEM.
Electric Sliding Roof
The global closing function is monitored by the
GEM.

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DIAGNOSIS AND TESTING

Generic Electronic Module (GEM)

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 419-10 for

– Turn signals (right, left, hazard warning lights)
schematic and connector information.
– Side lights
– Intermittent wipe, windshield
Description of operation – Wash/wipe system, windshield
A diagnosis of the generic electronic module – Rear wiper
(GEM) can be performed with WDS. – Wash/wipe system, rear window
Furthermore, an integrated service mode enables – Doors open/closed
testing of the input and output signals without the
need for further tools. To enable activation of – Remote release switch in the centre console
service mode: for the tailgate / luggage compartment lid
– Tailgate / luggage compartment lid release
– switch off the ignition and all other electrical button in the tailgate / luggage compartment
loads, lid
– apply the handbrake, – Open the tailgate / luggage compartment lid
– engage neutral or, on an automatic with a key.
transmission, move the selector lever to "P", – Locking key on the remote control (the
– click the driver's side seat belt into the buckle ignition key must not be in the ignition during
(Japan only), the test)
– and close the doors. – Release key on the remote control (the
and close the doors. ignition key must not be in the ignition during
the test)
Activating the service mode
– Tailgate / luggage compartment lid release
Proceed as follows to activate the service mode: key on the remote control (the ignition key
must not be in the ignition during the test)
NOTE: If the alarm sounds (in vehicles fitted with
an anti-theft alarm system), service mode cannot – Hood open/closed (in vehicles equipped with
be activated. an anti-theft alarm system)
– Switch the ignition to the "On" position. – Heated rear window
– Switch the ignition to the "Off" position. – Heated windshield (if equipped)
– PRESS and HOLD the rear window heater – Ignition on
switch – Automatic transmission, selector lever
– Switch the ignition to the "On" position. position "P"
– RELEASE the rear window heater switch – Driver's side seatbelt (Japan only)
– Reverse gear (Japan only)
A signal sounds and the turn signal lamps come
on to indicate that service mode has been An acoustic signal sounds and the turn signal
successfully activated. lamps flash to indicate receipt of each input
signal by the generic electronic module (GEM).
Input signals
Output signals
SWITCH the wiper switch to the "Off" position to
test the input signals. The following is a list of the SWITCH the wiper switch to the "Intermittent
signals to be tested, in no particular order: wipe" position to test the output signals.
PRESSING the rear window heater switch
activates or deactivates the output signals in the
following order:

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DIAGNOSIS AND TESTING (Continued)

– Front wipers (a signal sounds and the Diagnosis and Testing

direction indicator lamps flash when the
1. CHECK the concern.
"Park" position is reached)
2. Visually inspect for obvious signs of
– Rear window heater
mechanical or electricaldamage.
– Interior light(s) (the switch for the interior
lights must be in the "Door contact" setting) — Visual Inspection Chart
– "Door ajar" warning lamp in the instrument Electrical
cluster
Fuse(s).
– Rear window wiper Wiring harness
– Windscreen heater (only activated if the Electrical connector(s).
engine is running)
3. If an obvious cause for an observed or
– "Seatbelt" warning lamp in the instrument reported concern is found,correct the cause
cluster (Japan only) (if possible) before proceeding to the next
– Front wiper step. CHECK the operation of the system.
– etc. 4. If the concern persists after the visual
Ending the service mode inspection, CARRY OUT a fault diagnosis on
The GEM automatically exits the service mode the generic electronic module (GEM) with
20 seconds after the last input or if the vehicle is WDS and RECTIFY any displayed faults in
driven. This is indicated with 3 acoustic signals accordance with the fault description.
and by flashing of the turn signal lamps. CHECK the operation of the system.
5. If no faults are stored in the fault memory,
proceed with the Symptom Chart according
to the fault symptom.
Symptom Chart

Condition Possible Sources Action

• Service mode cannot be acti- • Fuse(s). • GO to Pinpoint Test A
vated • Circuit(s).
• Generic electronic module
(GEM)
• Rear window heater switch
• Generic electronic module • Fuse(s). • REFER to Section 418-00.
(GEM) not communicating with • Circuit(s).
the diagnostic unit • Generic electronic module
(GEM)

Pinpoint Test
PINPOINT TEST A: SERVICE MODE CANNOT BE ACTIVATED
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FUSE F24.
1 Key in OFF position.
2 CHECK Fuse F24 (BJB).
• Is the fuse OK?
→ Yes
GO to A2
→ No
RENEW fuse F24 (20 A). CHECK the sys-
tem again. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A2: MEASURE THE VOLTAGE AT FUSE F24
1 Connect Fuse F24 (BJB).
2 Measure the voltage between fuse F24 (20 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to A3
→ No
REPAIR the voltage supply to fuse F24 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
A3: CHECK FUSE F25
1 CHECK Fuse F25 (BJB).
• Is the fuse OK?
→ Yes
GO to A4
→ No
RENEW fuse F25 (15 A). CHECK the sys-
tem again. If the fuse blows again, LOCATE
and RECTIFY the short to ground with the
aid of the Wiring Diagrams.
A4: MEASURE THE VOLTAGE AT FUSE F25
1 Connect Fuse F25 (BJB).
2 Measure the voltage between fuse F25 (15 A)
and ground.
• Does the meter display battery voltage?
→ Yes
GO to A5
→ No
REPAIR the voltage supply to fuse F25 with
the aid of the Wiring Diagrams. CHECK the
operation of the system.
A5: CHECK THE VOLTAGE AT THE GENERIC ELECTRONIC MODULE (GEM)
1 Disconnect GEM C426.
2 Measure the voltage between the GEM, con-
nector C426, pin 1, circuit 29-AA17 (OG/WH),
wiring harness side and ground.

• Does the meter display battery voltage?

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to A6
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the GEM and fuse F24 with the
aid of the Wiring Diagrams. CHECK the op-
eration of the system.
A6: CHECK THE VOLTAGE AT THE GEM
1 Measure the voltage between the GEM, con-
nector C426, pin 5, circuit 29-LG25 (OG/BU),
wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
GO to A7
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the GEM and fuse F25 with the
aid of the Wiring Diagrams. CHECK the op-
eration of the system.
A7: CHECK THE VOLTAGE AT THE GEM
1 Connect GEM C426.
2 Disconnect GEM C429.
3 Key in ON position.
4 Measure the voltage between the GEM, con-
nector C429, pin 12, circuit 8-AA30 (WH), wir-
ing harness side and ground.

• Is a voltage of at least 10 Volts measured?

→ Yes
GO to A8
→ No

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the break in circuit
8-AA30 (WH) between the instrument clus-
ter and the GEM with the aid of the Wiring
Diagrams. CHECK the operation of the sys-
tem.
A8: CHECK THE GROUND CONNECTION OF THE GEM
1 Key in OFF position.
2 Measure the resistance between the GEM,
connector C429, pin 1, circuit 91-DK20
(BK/RD), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to A9
→ No
LOCATE and RECTIFY the break in circuit
91-DK20 (BK/RD) between the GEM and
ground connection G203 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
A9: CHECK THE GROUND CONNECTION OF THE GEM
1 Disconnect GEM C427.
2 Measure the resistance between the GEM,
connector C427, pin 5, circuit 31-DK20 (BK),
wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to A10
→ No

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the break in circuit
31-DK20 (BK) between the GEM and
ground connection G205 with the aid of the
Wiring Diagrams. CHECK the operation of
the system.
A10: CHECK THE GROUND CONNECTION VIA THE REAR WINDOW HEATER SWITCH
1 Press and hold the rear window heater switch.
2 Measure the resistance between the GEM,
connector C429, pin 20, circuit 31S-HB22
(BK/GN), wiring harness side and ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to A11
→ No
GO to A13
A11: CHECK THE GROUND CONNECTION VIA THE REAR WINDOW HEATER SWITCH
1 Release the rear window heater switch.
2 Measure the resistance between the GEM,
connector C429, pin 20, circuit 31S-HB22
(BK/GN), wiring harness side and ground.

• Is a resistance of more than 10 kOhms meas-

ured?
→ Yes
CHECK the GEM and RENEW as neces-
sary. CHECK the operation of the system.
→ No
GO to A12

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A12: CHECK THE CIRCUIT BETWEEN THE GEM AND THE REAR WINDOW HEATER SWITCH
FOR A SHORT TO GROUND
1 Disconnect Rear window heater switch C488.
2 Measure the resistance between the GEM,
connector C429, pin 20, circuit 31S-HB22
(BK/GN), wiring harness side and ground.

• Is a resistance of more than 10 kOhms meas-

ured?
→ Yes
RENEW the rear window heater switch.
CHECK the operation of the system.
→ No
LOCATE and RECTIFY the short to ground
in circuit 31S-HB22 (BK/GN) between the
GEM and the rear window heater switch
with the aid of the Wiring Diagrams. CHECK
the operation of the system.
A13: CHECK THE CIRCUIT BETWEEN THE GEM AND THE REAR WINDOW HEATER SWITCH
FOR OPEN CIRCUIT
1 Disconnect Rear window heater switch C488.
2 Measure the resistance between the GEM,
connector C429, pin 20, circuit 31S-HB22
(BK/GN), wiring harness side and the rear win-
dow heater switch, connector C488, pin 2, cir-
cuit 31S-HB22 (BK/GN), wiring harness side.

• Is a resistance of less than 2 Ohm measured?

→ Yes
GO to A14
→ No

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and RECTIFY the break in circuit
31S-HB22 (BK/GN) between the GEM and
the rear window heater switch with the aid of
the Wiring Diagrams. CHECK the operation
of the system.
A14: CHECK THE CIRCUIT BETWEEN THE REAR WINDOW HEATER SWITCH AND GROUND
FOR OPEN CIRCUIT
1 Measure the resistance between the rear win-
dow heater switch, connector C488, pin 1, cir-
cuit 31-HB22 (BK), wiring harness side and
ground.

• Is a resistance of less than 2 Ohm measured?

→ Yes
RENEW the rear window heater switch.
CHECK the operation of the system.
→ No
LOCATE and RECTIFY the break in the cir-
cuit between the rear window heater switch
and ground connection G204 with the aid of
the Wiring Diagrams. CHECK the operation
of the system.

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REMOVAL AND INSTALLATION

Generic Electronic Module (GEM)

REMOVAL AND INSTALLATION

Removal 3. Remove the glove compartment.

Left-hand drive vehicles 1. Press the sides towards the centre to
1. Remove the bottom footwell trim (5 clips). release the glove compartment.
2. Pull the glove compartment out of the
hinges.

2. Detach the opening damper from the glove

compartment.
1. Open the glove compartment to gain All vehicles
access to the opening damper. 4. Pull off the GEM connector.
2. Slide the upper part of the opening damper
away from the glove compartment.

5. Remove the GEM.

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419-10-15 Multifunction Electronic Modules 419-10-15

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Initialise the GEM with WDS after
installation.
Install the components in reverse order.

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 Group

SECTION TITLE PAGE

Body
Front End Body Panels.......................................................................................................... 501-02-1
Body Closures....................................................................................................................... 501-03-1
Interior Trim and Ornamentation............................................................................................ 501-05-1
Rear View Mirrors.................................................................................................................. 501-09-1
Seating.................................................................................................................................. 501-10-1
Glass, Frames and Mechanisms ........................................................................................... 501-11-1
Instrument Panel and Console .............................................................................................. 501-12-1
Handles, Locks, Latches and Entry Systems......................................................................... 501-14-1
Wipers and Washers ............................................................................................................. 501-16-1
Roof Opening Panel .............................................................................................................. 501-17-1
Bumpers................................................................................................................................ 501-19-1
Safety Belt System ................................................................................................................ 501-20A-1
Supplemental Restraint System ............................................................................................ 501-20B-1
Frame and Mounting
Uni-Body, Subframe and Mounting System ........................................................................... 502-00-1

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501-02-1 Front End Body Panels 501-02-1

SECTION 501-02 Front End Body Panels

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-02-2

GENERAL PROCEDURES

Hood Alignment............................................................................................ (41 213 0) 501-02-3

REMOVAL AND INSTALLATION

Fender.......................................................................................................... (44 252 0) 501-02-7

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501-02-2 Front End Body Panels 501-02-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Fender splash shield retaining bolts 3 - 27
Fender splash shield retaining screws 3 - 27
Fender front retaining bolts 7 - 62
Fender inner retaining bolts to the a-pillar 7 - 62
Fender lower retaining bolt to the a-pillar 7 - 62
Fender upper retaining bolt to the a-pillar 6 - 53
Fender flange bolts 7 - 62
Fender grille opening panel bolts 25 18 -
Hood latch to the grille opening panel 8 - 71
Windshield wiper arm retaining nuts 22 16 -
Hood hinge retaining bolts to the body 25 18 -
Hood hinge retaining bolts to the hood 25 18 -

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501-02-3 Front End Body Panels 501-02-3

GENERAL PROCEDURES

Hood Alignment (41 213 0)

GENERAL PROCEDURES

1. Remove the radiator grille.

4. Remove the cowl trim panel.

2. NOTE: The hood must be adjusted with the

5. Remove the resonator and the hood
hood latch removed.
insulator.
Remove the hood latch. • Release the clips.

3. NOTE: Make sure that the windshield wiper 6. Remove the plastic clip from the body
motor is in the park position. mounted hinge part.
Remove the windshield wiper arms. • Loosen the body mounted hinge retaining
• Lift up the covers. bolts. Using the centre position of the body
holes, tighten the bolts on both sides.

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501-02-4 Front End Body Panels 501-02-4

GENERAL PROCEDURES (Continued)

9. Tighten the hood hinge retaining bolts on
7. Loosen the hood hinge retaining bolts to
both sides.
finger tight.

8. Align the hood. 10. CAUTION: Support the hood with a

suitable wooden block to prevent the
• Adjust the hood so that the edges of the
hood from closing.
fender and the edge of the hood line up.
Check that the clearances with the left and Remove the hood support strut.
right-hand fenders run parallel and correct • Release the clips on both sides of the hood
as necessary. support strut.
• The clearances with the fenders must be
the same width on the left and right-hand
sides. The clearances can be equalised by
opening the hood and pushing the hood to
the left or right.

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501-02-5 Front End Body Panels 501-02-5

GENERAL PROCEDURES (Continued)

11. Loosen the body mounted hinge

14. Install the hood support strut.
retaining bolts and move hinges to
uppermost position.
• Tighten the retaining bolts until hinges
keep position.

15. Adjust the front of the hood flushness to

the fenders and the headlamps by screw-
ing the bump stop rubbers in or out.
12. Align the hood height to the height of the
fender by pushing down the rear edges of
the hood.

16. NOTE: All adjustment must be carried out

before installing the hood latch.
Install the hood latch.
13. Tighten the hood rear hinge retaining • The hood latch must be installed so that
bolts on both sides, to eliminate any the hood engages without stress and the
movement. clearances on the left and right-hand sides
• Install the clip on both sides to pretension remain equal.
the hinges.

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501-02-6 Front End Body Panels 501-02-6

GENERAL PROCEDURES (Continued)

17. Install the hood insulator and the resona- 20. Install the radiator grille.
tor.

18. Install the cowl trim panel.

19. NOTE: Make sure that the windshield wiper

motor is in the park position.
Install the windshield wiper arms.
• Clip on the covers.

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501-02-7 Front End Body Panels 501-02-7

REMOVAL AND INSTALLATION

Fender (44 252 0)

REMOVAL AND INSTALLATION

Removal 7. Disconnect the direction indicator electri-

cal connector.
1. NOTE: This procedure is for removing the
right-hand fender. The procedure for removing
the left hand fender is similar.
Remove the front bumper. For additional
information, refer to Section 501-19.
2. Remove the headlamps. For additional
information, refer to Section 417-01.
3. Raise and support the vehicle. For
additional information, refer to Section
100-02.
4. Remove the wheel and tire. For additional
information, refer to Section 204-04.
5. Remove the fender splash shield.
1. Remove the retaining screws.
8. Remove the fender front sound insulator.
2. Remove the retaining bolts (two bolts).
3. Remove the plastic fixings (three fixings).

6. Remove the fender front retaining bolts.

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501-02-8 Front End Body Panels 501-02-8

REMOVAL AND INSTALLATION (Continued)

9. Remove the fender inner retaining bolts 11. Remove the fender flange bolts and the
and the fender lower retaining bolt from fender grille opening panel bolt.
the a-pillar.

Installation
1. To install, reverse the removal procedure

10. Remove the fender upper retaining bolt

from the a-pillar.

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501-03-1 Body Closures 501-03-1

SECTION 501-03 Body Closures

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-03-2

GENERAL PROCEDURES

Luggage Compartment Lid Alignment................................................................................ 501-03-3

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501-03-2 Body Closures 501-03-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Door check strap to door pillar retaining bolts 23 17 –
Door check strap to door retaining bolts 6 – 53
Door striker plate retaining bolts 28 21 –
Door hinge retaining bolts 35 26 –
Luggage compartment hinge retaining bolts 23 17 –
Liftgate hinge retaining bolts 11 8 –

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501-03-3 Body Closures 501-03-3

GENERAL PROCEDURES

Luggage Compartment Lid Alignment

GENERAL PROCEDURES

4. Remove the luggage compartment lid sup-

General Equipment port struts.

4 mm Margin Blades
1. Loosen the luggage compartment lid
striker plate retaining bolts.

5. Adjust the luggage compartment lid hinge

to align the luggage compartment lid hinge
to body retaining bolts centrally in the
hinge holes.
2. Remove the luggage compartment lid
opening weatherstrip.

6. Loosen the luggage compartment lid to

hinge retaining bolts.
3. Remove the luggage compartment lid
bump stops.

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501-03-4 Body Closures 501-03-4

GENERAL PROCEDURES (Continued)

7. NOTE: Make sure the luggage compartment 10. Loosen the luggage compartment lid
lid is in the fully closed position. hinge to body retaining bolts.
Align the luggage compartment lid by in-
serting 4 mm margin blades between the
outer edges of the luggage compartment
lid and the rear quarter panels.

11. NOTE: Make sure the luggage compartment

lid is in the fully closed position.
Push the luggage compartment lid in the
hinge area until it aligns 2 mm below
8. Remove the 4 mm margin blades. flush with the rear quarter panel.
9. CAUTION: While opening the luggage
compartment lid, make sure it does
not move on the hinges.
Open the luggage compartment lid and
tighten the luggage compartment lid to
hinge retaining bolts.

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501-03-5 Body Closures 501-03-5

GENERAL PROCEDURES (Continued)

15. Install the luggage compartment lid open-

12. CAUTION: While opening the luggage ing weatherstrip.
compartment lid, make sure the
luggage compartment lid hinge does
not move.
Open the luggage compartment lid and
tighten the luggage compartment lid
hinge to body retaining bolts.

16. Fully close the luggage compartment.

17. Open the luggage compartment lid and
tighten the luggage compartment lid
striker plate retining bolts.

13. Install the luggage compartment lid sup-

port struts.

18. NOTE: Make sure the luggage compartment

lid is in the fully closed position.
Check the alignemnt of the luggage
compartment lid.
14. Install the luggage compartment lid bump
stops.

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501-05-1 Interior Trim and Ornamentation 501-05-1

SECTION 501-05 Interior Trim and Ornamentation

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-05-2

REMOVAL AND INSTALLATION

A-Pillar Trim Panel........................................................................................ (43 616 0) 501-05-3

Headliner — Vehicles Without: Diversity Antenna......................................... (43 612 0) 501-05-4
Headliner — Vehicles With: Diversity Antenna ............................................. (43 612 0) 501-05-12
Front Door Trim Panel .................................................................................. (43 705 0) 501-05-23
Rear Door Trim Panel................................................................................... (43 706 0) 501-05-25

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501-05-2 Interior Trim and Ornamentation 501-05-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Safety belt upper anchor retaining bolt 38 28 -

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501-05-3 Interior Trim and Ornamentation 501-05-3

REMOVAL AND INSTALLATION

A-Pillar Trim Panel (43 616 0)

REMOVAL AND INSTALLATION

Removal
2. WARNING: Make sure the A-pillar trim
Vehicles with side air curtains panel retaining strap is correctly
attached to the A-pillar trim panel.
1. NOTE: The A-pillar trim panel is secured to the
Failure to follow this instruction may
top of the A-pillar by a retaining strap. The
result in personal injury.
retaining strap must be detached from the A-
pillar before the A-pillar trim panel is removed. Install the A-pillar trim panel.
Remove the A-pillar trim panel.

Vehicles without side air curtains

3. Install the A-pillar trim panel.
Vehicles without side air curtains
2. Remove the A-pillar trim panel.

Installation
Vehicles with side air curtains
1. Inspect the A-pillar trim panel and
retaining strap. If the A-pillar trim panel or
retaining strap are damaged or broken
install new parts as necessary.

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501-05-4 Interior Trim and Ornamentation 501-05-4

REMOVAL AND INSTALLATION

Headliner — Vehicles Without: Diversity Antenna (43 612 0)

4. Fully open the glove compartment.
• Press the sides of the glove compartment
General Equipment towards the center to release the glove
compartment stops.
Draw cord with a minimum length of one meter

Removal
All vehicles
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the A-pillar trim panels. For
additional information, refer to A-Pillar
Trim Panel in this section.
Right-hand drive vehicles
3. Detach the damper from the glove
compartment. 5. Remove the glove compartment.
1. Open the glove compartment to access the • Detach the hinges.
damper.
2. Push the top of the damper away from the
glove compartment.

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501-05-5 Interior Trim and Ornamentation 501-05-5

REMOVAL AND INSTALLATION (Continued)

Left-hand drive vehicles

9. NOTE: The lower fixing is located below the
6. Remove the instrument panel lower panel.
instrument panel and can only be viewed from
1. Remove the instrument panel lower panel outside the vehicle.
retaining screws.
Detach the interior lighting wiring harness
2. Release the instrument panel lower panel
from the A-pillar.
retaining clips.

All vehicles
7. Detach the interior lighting wiring harness
from the central junction box (CJB) and
disconnect the electrical connector.

10. Detach the interior lighting wiring har-

ness from the A-pillar.

8. Attach a suitable draw cord to the interior

lighting wiring harness electrical connec-
tor.

11. Pull the interior lighting wiring harness

through the instrument panel to expose
the electrical connector and the attached
wire.

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501-05-6 Interior Trim and Ornamentation 501-05-6

REMOVAL AND INSTALLATION (Continued)

12. Remove the passenger assist handles.
16. Remove the sun visors.

13. Move the front safety belt shoulder height

17. Remove the sun visor retaining clips.
adjuster to its lowest position.
14. Detach the door opening weatherstrips
from the B-pillars.

Vehicles with power roof opening panel

18. Remove the roof opening panel weather-
strip.
15. Detach the B-pillar upper trim panels
from the B-pillars and position them to
one side.
1. Detach the locating tangs from the B-pillar
lower trim panel.
2. Remove the screw cover.
3. Remove the retaining screw.

All vehicles
19. Remove the overhead console. For
additional information, refer to Section
501-12.

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501-05-7 Interior Trim and Ornamentation 501-05-7

REMOVAL AND INSTALLATION (Continued)

Vehicles with auto-dimming interior mirror 23. Disconnect the electrical connectors and
20. Disconnect the interior mirror electrical remove the rear interior lamp (if
connector (if equipped). equipped).

Vehicles with power roof opening panel 24. Pull down on the rear interior lamp
21. Partially lower the headliner and discon- opening to detach the headliner spacer
nect the roof opening panel motor elec- glue fixing from the roof panel.
trical connector (headliner shown re- 5-door
moved for clarity). 25. Detach the rear door opening weather-
strips from the C-pillars.

All vehicles
22. Detach the rear interior lamp (if 26. Detach the liftgate opening weatherstrip
equipped). from the C-pillars.

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501-05-8 Interior Trim and Ornamentation 501-05-8

REMOVAL AND INSTALLATION (Continued)

27. Remove the C-pillar upper trim panel 30. Remove the C-pillar lower trim panels
retaining screws. (vehicle with trim panel shown, vehicles
• Remove the blanking plugs and retaining with seat bolster similar).
screws. • Remove the C-pillar lower trim panel re-
taining screw.

28. Remove the C-pillar upper trim panels.

• Detach the retaining clips. 31. Fold down the rear seat backrests.
32. Remove the rear seat backrest latch cov-
ers.

4-door
29. Detach the rear door opening weather-
strips from the C-pillars. 33. Detach the parcel shelf trim panel.

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501-05-9 Interior Trim and Ornamentation 501-05-9

REMOVAL AND INSTALLATION (Continued)

34. Detach the C-pillar upper trim panels Wagon

from the C-pillars and position them to 37. Detach the liftgate opening weatherstrip.
one side.

38. Remove the D-pillar trim retaining

35. Remove the high mounted stoplamp screws.
cover.

39. CAUTION: Disconnect the rear

36. Disconnect the high mounted stoplamp window washer tube from the right-
electrical connector and remove the high hand D-pillar trim panel.
mounted stoplamp.
Detach the D-pillar trim panel retaining
clips and remove the D-pillar trim panels.
40. Detach the rear door opening weather-
strip.

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501-05-10 Interior Trim and Ornamentation 501-05-10

REMOVAL AND INSTALLATION (Continued)

41. Remove the load space upper trim panel 43. CAUTION: The bolt securing the
retaining screws and remove the load safety belt anchor is held captive by a
space upper trim panels. paper washer. The bolt, spacer and
paper washer must remain on the
safety belt anchor at all times when
the safety belt is detached or
removed.
Detach the safety belt upper anchors.
1. Detach the trim panel.
2. Detach the safety belt upper anchors.

42. Disconnect the power outlet electrical

connector on the right-hand load space
upper trim panel (if equipped).

44. Remove the C-pillar trim panel.

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501-05-11 Interior Trim and Ornamentation 501-05-11

REMOVAL AND INSTALLATION (Continued)

5-door and wagon 5-door and wagon

45. Remove the headliner retaining clips. 49. Remove the headliner (5-door shown).

All vehicles 4-door

46. Detach the draw cord from the interior 50. Recline the front seat backrests to allow
lighting wiring harness electrical removal of the headliner through the
connector. passenger door opening.
47. Disconnect the rear window washer tube 51. Remove the headliner.
from the right-hand A-pillar.

48. Disconnect the rear window washer tube Installation

from the rear right-hand side of the head-
liner. NOTE: Make sure the front safety belt shoulder
height adjuster locking control is correctly located
on the safety belt shoulder height adjuster.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-05-12 Interior Trim and Ornamentation 501-05-12

REMOVAL AND INSTALLATION

Headliner — Vehicles With: Diversity Antenna (43 612 0)

4. Fully open the glove compartment.
• Press the sides of the glove compartment
General Equipment towards the center to release the glove
compartment stops.
Draw cord with a minimum length of one meter
Audio unit removal tools

Removal
All vehicles
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the A-pillar trim panels. For
additional information, refer to A-Pillar
Trim Panel in this section.
Right-hand drive vehicles
3. Detach the damper from the glove 5. Remove the glove compartment.
compartment. • Detach the hinges.
1. Open the glove compartment to access the
damper.
2. Push the top of the damper away from the
glove compartment.

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501-05-13 Interior Trim and Ornamentation 501-05-13

REMOVAL AND INSTALLATION (Continued)

Left-hand drive vehicles 8. Disconnect the diversity antenna cable

6. Remove the instrument panel lower panel. from the audio unit.
1. Remove the instrument panel lower panel
retaining screws.
2. Release the instrument panel lower panel
retaining clips.

9. Remove the left-hand trim panel from the

floor console.

All vehicles
7. Detach the audio unit from the instrument
panel.
1. Insert the audio unit removal tools.
2. Pull the audio unit removal tools outwards.
3. Detach the audio unit.

10. Detach the left-hand front door weather-

strip.

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501-05-14 Interior Trim and Ornamentation 501-05-14

REMOVAL AND INSTALLATION (Continued)

11. Detach the left-hand cowl trim. 14. Detach the left-hand lower B-pillar trim
panel.

12. Detach the left-hand rear door weather-

strip. 15. Detach the left-hand cowl trim panel.

13. Detach the left-hand cowl trim. 16. Lift the rear seat cushion.
17. Remove the left-hand cowl trim panel.

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501-05-15 Interior Trim and Ornamentation 501-05-15

REMOVAL AND INSTALLATION (Continued)

Right-hand drive vehicles 22. Detach the interior lighting wiring har-
18. Detach the floor covering. ness from the CJB and disconnect the
electrical connector.

Left-hand drive vehicles

19. Detach the floor covering. 23. Attach a suitable draw cord to the interior
lighting wiring harness electrical connec-
tor.

All vehicles
20. Detach the diversity antenna cable from
the floor.

21. Detach the central junction box (CJB) and

position to one side.

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501-05-16 Interior Trim and Ornamentation 501-05-16

REMOVAL AND INSTALLATION (Continued)

24. NOTE: The lower fixing is located below the 27. Attach a suitable draw cord to the
instrument panel and can only be viewed from diversity antenna cable.
outside the vehicle. 28. Pull the diversity antenna cable up the A-
Detach the interior lighting wiring har- pillar to expose the suitable draw cord.
ness from the A-pillar. 29. Detach the draw cord from the diversity
antenna cable.
30. Remove the passenger assist handles.

31. Move the front safety belt shoulder height

adjuster to its lowest position.
32. Detach the door opening weatherstrips
from the B-pillars.

25. Detach the interior lighting wiring har-

ness and diversity antenna cable from
the A-pillar.

26. Pull the interior lighting wiring harness

through the instrument panel to expose
the electrical connector and the attached
wire.

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501-05-17 Interior Trim and Ornamentation 501-05-17

REMOVAL AND INSTALLATION (Continued)

33. Detach the B-pillar upper trim panels Vehicles with power roof opening panel
from the B-pillars and position them to 36. Remove the roof opening panel weather-
one side. strip.
1. Detach the locating tangs from the B-pillar
lower trim panel.
2. Remove the screw cover.
3. Remove the retaining screw.

All vehicles
37. Remove the overhead console. For
additional information, refer to Section
501-12.
Vehicles with auto-dimming interior mirror
34. Remove the sun visors.
38. Disconnect the interior mirror electrical
connector.

35. Remove the sun visor retaining clips.

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501-05-18 Interior Trim and Ornamentation 501-05-18

REMOVAL AND INSTALLATION (Continued)

Vehicles with power roof opening panel 42. Pull down on the rear interior lamp
39. Partially lower the headliner and discon- opening to detach the headliner spacer
nect the roof opening panel motor elec- glue fixing from the roof panel.
trical connector (headliner shown re- 5-door
moved for clarity). 43. Detach the rear door opening weather-
strips from the C-pillars.

All vehicles
40. Detach the rear interior lamp (if 44. Detach the liftgate opening weatherstrip
equipped). from the C-pillars.

41. Disconnect the electrical connectors and 45. Remove the C-pillar upper trim panel
remove the rear interior lamp (if retaining screws.
equipped).
• Remove the blanking plugs and retaining
screws.

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501-05-19 Interior Trim and Ornamentation 501-05-19

REMOVAL AND INSTALLATION (Continued)

46. Remove the C-pillar upper trim panels. 50. Remove the rear seat backrest latch cov-
• Detach the retaining clips. ers.

4-door 51. Detach the parcel shelf trim panel.

47. Detach the rear door opening weather-
strips from the C-pillars.

52. Detach the C-pillar upper trim panels

from the C-pillars and position them to
48. Remove the C-pillar lower trim panels one side.
(vehicle with trim panel shown, vehicles
with seat bolster similar).
• Remove the C-pillar lower trim panel re-
taining screw.

49. Fold down the rear seat backrests.

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501-05-20 Interior Trim and Ornamentation 501-05-20

REMOVAL AND INSTALLATION (Continued)

53. Remove the high mounted stoplamp 56. Remove the D-pillar trim retaining
cover. screws.

54. Disconnect the high mounted stoplamp 57. CAUTION: Disconnect the rear
electrical connector and remove the high window washer tube from the right-
mounted stoplamp. hand D-pillar trim panel.
Detach the D-pillar trim panel retaining
clips and remove the D-pillar trim panels.
58. Detach the rear door opening weather-
strip.

Wagon
55. Detach the liftgate opening weatherstrip.

59. Remove the load space upper trim panel

retaining screws and remove the load
space upper trim panels.

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501-05-21 Interior Trim and Ornamentation 501-05-21

REMOVAL AND INSTALLATION (Continued)

62. Remove the C-pillar trim panel.

60. Disconnect the power outlet electrical
connector on the right-hand load space
upper trim panel (if equipped).

63. Disconnect the diversity antenna cable

connector from the rear quarter window
glass.
61. CAUTION: The bolt securing the 5-door and wagon
safety belt anchor is held captive by a 64. Remove the headliner retaining clips.
paper washer. The bolt, spacer and
paper washer must remain on the
safety belt anchor at all times when
the safety belt is detached or
removed.
Detach the safety belt upper anchors.
1. Detach the trim panel.
2. Detach the safety belt upper anchors.

All vehicles
65. Detach thedraw cordfrom the interior
lighting wiring harness electrical
connector.
66. Disconnect the rear window washer tube
from the right-hand A-pillar.

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501-05-22 Interior Trim and Ornamentation 501-05-22

REMOVAL AND INSTALLATION (Continued)

67. Disconnect the rear window washer tube
from the rear right-hand side of the head-
liner. Installation
NOTE: Make sure the front safety belt shoulder
height adjuster locking control is correctly located
on the safety belt shoulder height adjuster.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

4-door and 5-door

68. Disconnect the diversity antenna cable
from the roof panel.
5-door and wagon
69. Remove the headliner (5-door shown).

4-door
70. Recline the front seat backrests to allow
removal of the headliner through the
passenger door opening.
71. Remove the headliner.

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501-05-23 Interior Trim and Ornamentation 501-05-23

REMOVAL AND INSTALLATION

Front Door Trim Panel (43 705 0)

Removal 3. Remove the front door latch remote

control handle bezel.
1. Detach the exterior mirror trim panel.
1. Remove the screw cover.
1. Remove the screw cover.
2. Remove the screw.
2. Remove the screw.

4. Remove the door pull handle cover.

2. Disconnect the exterior mirror control
switch electrical connector and remove the
exterior mirror trim panel.

5. Remove the retaining screws.

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501-05-24 Interior Trim and Ornamentation 501-05-24

REMOVAL AND INSTALLATION (Continued)

6. Remove the door trim panel retaining
screws.

7. Detach the door trim panel.

8. Disconnect the power window electrical

connector and remove the door trim panel.

Installation
1. To install, reverse the removal procedure.

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501-05-25 Interior Trim and Ornamentation 501-05-25

REMOVAL AND INSTALLATION

Rear Door Trim Panel (43 706 0)

Removal Vehicles with manual windows

4. Remove the window regulator handle.
All vehicles
1. Remove the rear door latch remote control • Use a suitable piece of wire.
handle bezel.
1. Remove the screw cover.
2. Remove the screw.

5. Remove the door trim panel retaining

screws.

2. Remove the door pull handle cover.

6. Remove the door trim panel.

3. Remove the retaining screw.

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501-05-26 Interior Trim and Ornamentation 501-05-26

REMOVAL AND INSTALLATION (Continued)

Vehicles with power windows
7. Remove the door trim panel retaining
screws.

8. Detach the door trim panel.

9. Disconnect the power window electrical

connector and remove the door trim panel.

Installation
1. To install, reverse the removal procedure.

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501-09-1 Rear View Mirrors 501-09-1

SECTION 501-09 Rear View Mirrors

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-09-2

DIAGNOSIS AND TESTING

Rear View Mirrors.............................................................................................................. 501-09-3

Inspection and Verification ............................................................................................... 501-09-3
Pinpoint Tests .................................................................................................................. 501-09-3

REMOVAL AND INSTALLATION

Exterior Mirror............................................................................................... (43 364 0) 501-09-18

Auto-dimming Interior Mirror .............................................................................................. 501-09-19

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501-09-2 Rear View Mirrors 501-09-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Exterior mirror retaining screws 2 - 18

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501-09-3 Rear View Mirrors 501-09-3

DIAGNOSIS AND TESTING

Rear View Mirrors

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 501-09 for Mechanical Electrical

schematic and connector information. Exterior mirror(s) Fuse(s)
Relay
Electrical connector(s)
Inspection and Verification Switch
1. Verify the customer concern. 3. If an obvious cause for an observed or
2. Visually inspect for obvious signs of reported concern is found, correct the cause
mechanical or electrical damage. (if possible) before proceeding to the next
step.
Visual Inspection Chart 4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Condition Possible Sources Action
• The mirrors are inoperative • Exterior mirror control switch. • CARRY OUT the Exterior Mirror
Control Switch Component Test.
REFER to the Wiring Diagrams.
• Circuit(s). • GO to Pinpoint Test A.
• A single mirror is inoperative • Exterior mirror control switch. • CARRY OUT the Exterior Mirror
Control Switch Component Test.
REFER to the Wiring Diagrams.
• Exterior mirror motor(s). • GO to Pinpoint Test B.
• Circuit(s).
• A single mirror does not function • Exterior mirror control switch. • CARRY OUT the Exterior Mirror
with switch logic Control Switch Component Test.
REFER to the Wiring Diagrams.
• Exterior mirror motor(s). • GO to Pinpoint Test C.
• Circuit(s).
• The heated exterior mirror does • Heated rear window control • CARRY OUT the Heated Rear
not defrost switch. Window Control Switch Compo-
nent Test. REFER to the Wiring
Diagrams.
• Relay. • GO to Pinpoint Test D.
• Heated mirror element(s).
• Circuit(s).
• The power folding mirrors do not • Power fold mirror module. • GO to Pinpoint Test E.
operate • Circuit(s).
• The power folding mirrors do not • Power fold mirror motor(s). • GO to Pinpoint Test F
operate correctly • Circuit(s).
• The auto-dimming interior mirror • Auto-dimming interior mirror. • GO to Pinpoint Test G
does not operate correctly • Circuit(s).

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.

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501-09-4 Rear View Mirrors 501-09-4

DIAGNOSIS AND TESTING

PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE

CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE VOLTAGE TO THE EXTERIOR MIRROR CONTROL SWITCH
1 Disconnect Exterior Mirror Control Switch
C733.
2 Measure the voltage between the exterior mir-
ror control switch C733 pin 6, circuit 29-AD12
(OG/YE), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A2.
→ No
REPAIR circuit 29-AD12 (OG/YE). TEST
the system for normal operation.
A2: CHECK THE EXTERIOR MIRROR CONTROL SWITCH GROUND CIRCUIT FOR CONTINUITY
1 Measure the resistance between the exterior
mirror control switch C733 pin 4, circuit 31-
AD12 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 31-AD12 (BK). TEST the
system for normal operation.
PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE EXTERIOR MIRROR MOTOR CIRCUIT FOR CONTINUITY
1 Disconnect Exterior Mirror Control Switch
C733.

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501-09-5 Rear View Mirrors 501-09-5

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
NOTE: LHD Driver Exterior Mirror
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH) and pin 1, circuit 33-
AD32 (YE/RD), harness side.
NOTE: LHD Passenger Exterior Mirror
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN) and pin 2, circuit
33-AD30 (YE/BK), harness side.
NOTE: RHD Driver Exterior Mirror
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH) and pin 2, circuit 33-
AD30 (YE/BK), harness side.
NOTE: RHD Passenger Exterior Mirror
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN) and pin 1, circuit
33-AD32 (YE/RD), harness side.
• Is the resistance between 70 and 125 ohms?
→ Yes
VERIFY the customer concern.
→ No
GO to B2.
B2: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND
THE EXTERIOR MIRROR
1 Disconnect Driver Exterior Mirror C730 or Pas-
senger Exterior Mirror C731.
2 Measure the resistance between:
NOTE: Driver Exterior Mirror
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH), harness side and the
driver exterior mirror C730 pin 2, circuit 32-
AD16 (WH), harness side.
NOTE: Passenger Exterior Mirror
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN), harness side and
the passenger exterior mirror C731 pin 2, cir-
cuit 32-AD17 (WH/GN), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new exterior mirror. TEST the
system for normal operation.
→ No
REPAIR circuit 32-AD16 (WH) driver exte-
rior mirror, or circuit 32-AD17 (WH/GN) pas-
senger exterior mirror. TEST the system for
normal operation.

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501-09-6 Rear View Mirrors 501-09-6

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC
1 Key in ON position.
2 Operate the exterior mirror control switch.
• Does the exterior mirror function with switch
logic?
→ Yes
VERIFY the customer concern.
→ No
Driver exterior mirror up/down function in-
operative
GO to C2.
Driver exterior mirror left/right function inop-
erative
GO to C4.
Passenger exterior mirror up/down function
inoperative
GO to C6.
Passenger exterior mirror left/right function
inoperative
GO to C8.
C2: CHECK THE DRIVER EXTERIOR MIRROR UP/DOWN CIRCUIT
1 Key in OFF position.
2 Disconnect Exterior Mirror Control Switch
C733.
3 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH) and pin 1, circuit 33-
AD32 (YE/RD), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH) and pin 2, circuit 33-
AD30 (YE/BK), harness side.

• Is the resistance between 70 and 125 ohms?

→ Yes
VERIFY the customer concern.
→ No
GO to C3.
C3: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND
THE EXTERIOR MIRROR
1 Disconnect Driver Exterior Mirror C730.

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501-09-7 Rear View Mirrors 501-09-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 1,
circuit 33-AD32 (YE/RD), harness side and
the driver exterior mirror C730 pin 4, circuit
33-AD32 (YE/RD), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 2,
circuit 33-AD30 (YE/BK), harness side and
the driver exterior mirror C730 pin 4, circuit
33-AD30 (YE/BK), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new exterior mirror. TEST the
system for normal operation.
→ No
REPAIR circuit 33-AD32 (YE/RD) LHD (cir-
cuit 33-AD30 [YE/BK] RHD). TEST the sys-
tem for normal operation.
C4: CHECK THE DRIVER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
1 Key in OFF position.
2 Disconnect Exterior Mirror Control Switch
C733.
3 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH) and pin 7, circuit 33-
AD31 (YE/BU), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD16 (WH) and pin 5, circuit 33-
AD29 (YE/VT), harness side.

• Is the resistance between 70 and 125 ohms?

→ Yes
VERIFY the customer concern.
→ No
GO to C5.
C5: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND
THE EXTERIOR MIRROR
1 Disconnect Driver Exterior Mirror C730.

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501-09-8 Rear View Mirrors 501-09-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 7,
circuit 33-AD31 (YE/BU), harness side and
the driver exterior mirror C730 pin 5, circuit
33-AD31 (YE/BU), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 5,
circuit 33-AD29 (YE/VT), harness side and
the driver exterior mirror C730 pin 5, circuit
33-AD29 (YE/VT), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new exterior mirror. TEST the
system for normal operation.
→ No
REPAIR circuit 33-AD31 (YE/BU) LHD (cir-
cuit 33-AD29 [YE/VT] RHD). TEST the sys-
tem for normal operation.
C6: CHECK THE PASSENGER EXTERIOR MIRROR UP/DOWN CIRCUIT
1 Key in OFF position.
2 Disconnect Exterior Mirror Control Switch
C733.
3 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN) and pin 2, circuit
33-AD30 (YE/BK), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN) and pin 1, circuit
33-AD32 (YE/RD), harness side.

• Is the resistance between 70 and 125 ohms?

→ Yes
VERIFY the customer concern.
→ No
GO to C7.
C7: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND
THE EXTERIOR MIRROR
1 Disconnect Passenger Exterior Mirror C731.

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501-09-9 Rear View Mirrors 501-09-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 2,
circuit 33-AD30 (YE/BK), harness side and
the passenger exterior mirror C731 pin 4,
circuit 33-AD10 (YE/BK), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 1,
circuit 33-AD32 (YE/RD), harness side and
the passenger exterior mirror C731 pin 4, cir-
cuit 33-AD10 (YE/BK), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new exterior mirror. TEST the
system for normal operation.
→ No
REPAIR circuit 33-AD30 (YE/BK) LHD, (cir-
cuit 33-AD32 [YE/RD] RHD) or circuit 33-
AD10 (YE/BK). TEST the system for normal
operation.
C8: CHECK THE PASSENGER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
1 Key in OFF position.
2 Disconnect Exterior Mirror Control Switch
C733.
3 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN) and pin 5, circuit
33-AD29 (YE/VT), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 3,
circuit 32-AD17 (WH/GN) and pin 7, circuit
33-AD31 (YE/BU), harness side.

• Is the resistance between 70 and 125 ohms?

→ Yes
VERIFY the customer concern.
→ No
GO to C9.
C9: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND
THE EXTERIOR MIRROR
1 Disconnect Passenger Exterior Mirror C731.

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501-09-10 Rear View Mirrors 501-09-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
NOTE: LHD
- the exterior mirror control switch C733 pin 5,
circuit 33-AD29 (YE/VT), harness side and
the passenger exterior mirror C731 pin 5,
circuit 33-AD11 (YE/VT), harness side.
NOTE: RHD
- the exterior mirror control switch C733 pin 7,
circuit 33-AD31 (YE/BU), harness side and
the passenger exterior mirror C731 pin 5, cir-
cuit 33-AD11 (YE/VT), harness side.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new exterior mirror. TEST the
system for normal operation.
→ No
REPAIR circuit 33-AD29 (YE/VT) LHD, (cir-
cuit 33-AD31 [YE/BU] RHD) or circuit 33-
AD11 (YE/VT). TEST the system for normal
operation.
PINPOINT TEST D: THE HEATED EXTERIOR MIRROR DOES NOT DEFROST
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE HEATED EXTERIOR MIRROR DEFROSTS
1 Operate the heated rear window control switch.
• Does the heated exterior mirror defrost?
→ Yes
VERIFY the customer concern.
→ No
GO to D2.
D2: CHECK THE SUPPLY VOLTAGE TO THE INOPERATIVE EXTERIOR MIRROR
1 Disconnect Inoperative Exterior Mirror C730 or
C731.
2 Key in ON position.
3 Operate the heated rear window control switch.

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501-09-11 Rear View Mirrors 501-09-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between:
NOTE: Driver Exterior Mirror
- the driver exterior mirror C730 pin 1, circuit
15S-HB35 (GN/BK), harness side and
ground.
NOTE: Passenger Exterior Mirror
- the passenger exterior mirror C731 pin 1, cir-
cuit 15S-HB36 (GN/OG), harness side and
ground

• Is the voltage greater than 10 volts?

→ Yes
GO to D3
→ No
Repair circuit 15S-HB35 (GN/BK); or circuit
15S-HB36 (GN/OG). TEST the system for
normal operation.
D3: CHECK THE INOPERATIVE EXTERIOR MIRROR GROUND CIRCUIT FOR CONTINUITY
1 Key in OFF position.
2 Measure the resistance between:
NOTE: Driver exterior mirror
- the driver exterior mirror C730 pin 3, circuit
31–HB35 (BK), harness side and ground.
NOTE: Passenger exterior mirror
- the passenger exterior mirror C731 pin 3, cir-
cuit 31–HB36 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new heated exterior mirror
glass. TEST the system for normal opera-
tion.
→ No
REPAIR circuit 31-HB35 (BK) or circuit 31-
HB36 (BK). TEST the system for normal
operation.
PINPOINT TEST E: THE POWER FOLDING MIRRORS DO NOT OPERATE
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH AND
THE POWER FOLDING MIRROR MODULE
1 Disconnect Fuse 75.

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501-09-12 Rear View Mirrors 501-09-12

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Power Folding Mirror Module
C753.
3 Measure the resistance between the exterior
mirror control switch C733 pin 8, circuit 31S-
AD24 (BK/RD), harness side and the power
folding mirror module C753 pin 2, circuit 31S-
AD24 (BK/RD), harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to E2.
→ No
REPAIR circuit 31S-AD24 (BK/RD). TEST
the system for normal operation.
E2: CHECK THE POWER FOLDING MIRROR MODULE GROUND CIRCUIT FOR CONTINUITY
1 Measure the resistance between the power
folding mirror module C753 pin 5, circuit 31-
AD25 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to E3.
→ No
REPAIR circuit 31-AD25 (BK). TEST the
system for normal operation.
E3: CHECK THE VOLTAGE TO THE POWER FOLDING MIRROR MODULE
1 Connect Fuse 75.

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501-09-13 Rear View Mirrors 501-09-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the power fold-
ing mirror module C753 pin 4, circuit 29-AD25
(OG), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new power folding mirror mod-
ule. TEST the system for normal operation.
→ No
REPAIR circuit 29-AD25 (OG). TEST the
system for normal operation.
PINPOINT TEST F: THE POWER FOLDING MIRRORS DO NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE POWER FOLDING MIRROR
MOTOR AND THE POWER FOLDING MIRROR MODULE
1 Disconnect Inoperative Power Folding Mirror
Motor C730 or C731.
2 Measure the resistance between:
NOTE: LHD Driver power folding mirror
- the power folding mirror motor C730 pin 6,
circuit 32-AD26 (WH/GN), harness side and
the power folding mirror module C753 pin 3,
circuit 32-AD27 (WH/GN), harness side.
NOTE: LHD Passenger power folding mirror
- the power folding mirror motor C731 pin 6,
circuit 32-AD26 (WH/GN), harness side and
the power folding mirror module C753 pin 3,
circuit 32-AD28 (WH/GN), harness side.
NOTE: RHD Driver power folding mirror
- the power folding mirror motor C730 pin
6,circuit 32-AD26 (WH/GN), harness side and
the power folding mirror module C753 pin 3,
circuit 32-AD28 (WH/GN), harness side.
NOTE: RHD Passenger power folding mirror
- the power folding mirror motor C731 pin
6,circuit 32-AD26 (WH/GN), harness side and
power folding mirror module C753 pin 3, cir-
cuit 32-AD27 (WH/GN), harness side.
• Is the resistance less than 5 ohms?
→ Yes

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501-09-14 Rear View Mirrors 501-09-14

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to F2.
→ No
REPAIR circuit 32-AD26 (WH/GN); or circuit
32-AD27 (WH/GN); or circuit 32-AD28
(WH/GN). TEST the system for normal op-
eration.
F2: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE POWER FOLDING MIRROR
MOTOR AND THE POWER FOLDING MIRROR MODULE
1 Measure the resistance between:
NOTE: LHD Driver power folding mirror
- the power folding mirror motor C730 pin 7,
circuit 33-AD26 (YE/GN), harness side and
the power folding mirror module C753 pin 1,
circuit 33-AD27 (YE/GN), harness side.
NOTE: LHD Passenger power folding mirror
- the power folding mirror motor C731 pin 7,
circuit 33-AD26 (YE/GN), harness side and
the power folding mirror module C753 pin 1,
circuit 33-AD28 (YE/GN), harness side.
NOTE: RHD Driver power folding mirror
- the power folding mirror motor C730 pin 7,
circuit 33-AD26 (YE/GN), harness side and
the power folding mirror module C753 pin 1,
circuit 33-AD28 (YE/GN), harness side.
NOTE: RHD Passenger power folding mirror
- the power folding mirror motor C731 pin 7,
circuit 33-AD26 (YE/GN), harness side and
the power folding mirror module C753 pin 1,
circuit 33-AD27 (YE/GN), harness side.
• Is the resistance less than 5 ohms?
→ Yes
INSTALL a new power fold motor . TEST
the system for normal operation.
→ No
REPAIR circuit 33-AD26 (YE/GN); or circuit
33-AD27 (YE/GN); or circuit 33-AD28
(YE/GN). TEST the system for normal op-
eration.
PINPOINT TEST G: THE AUTO-DIMMING INTERIOR MIRROR DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
G1: CHECK FOR CONTINUITY BETWEEN THE AUTO-DIMMING INTERIOR MIRROR AND
GROUND
1 Disconnect Auto-dimming Interior Mirror C473.

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501-09-15 Rear View Mirrors 501-09-15

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the auto-
dimming interior mirror C473 pin 2, circuit 31-
AD15 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to G2
→ No
REPAIR circuit 31-AD15 (BK). TEST the
system for normal operation.
G2: CHECK THE VOLTAGE TO THE AUTO-DIMMING INTERIOR MIRROR
1 Key in ON position.
2 Measure the voltage between the auto-
dimming interior mirror C473 pin 1, circuit 15-
AD15 (GN/RD), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to G3
→ No
REPAIR circuit 15-AD15 (GN/RD). TEST
the system for normal operation.

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501-09-16 Rear View Mirrors 501-09-16

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
G3: CHECK THE REVERSE CUT-OUT VOLTAGE TO THE AUTO-DIMMING INTERIOR MIRROR
NOTE: Make sure the transmission is in
NEUTRAL.
1 Measure the voltage between the auto-
dimming interior mirror C473 pin 3, circuit 15S-
AD15 (GN/RD), harness side and ground.

• Is any voltage present?

→ Yes
GO to G4
→ No
GO to G5
G4: CHECK FOR VOLTAGE TO THE AUTO-DIMMING INTERIOR MIRROR
1 Key in OFF position.
2 Disconnect Transmission Switch C181 (man-
ual)/Transmission Range Sensor C187 (auto-
matic).
3 Key in ON position.
4 Measure the voltage between the auto-
dimming interior mirror C473 pin 3, circuit 15S-
AD15 (GN/RD), harness side and ground.

• Is any voltage present?

→ Yes
INSTALL a new transmission switch (man-
ual)/transmission range sensor (automatic).
TEST the system for normal operation.
→ No
REPAIR circuit 15S-AD15 (GN/RD). TEST
the system for normal operation.
G5: CHECK THE REVERSE CUT-OUT VOLTAGE TO THE AUTO-DIMMING INTERIOR MIRROR
1 Place the gearshift lever/selector lever in re-
verse.

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501-09-17 Rear View Mirrors 501-09-17

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the auto-
dimming interior mirror C473 pin 3, circuit 15S-
AD15 (GN/RD), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new auto-dimming interior mir-
ror. TEST the system for normal operation.
→ No
REPAIR circuit 15S-AD15 (GN/RD). TEST
the system for normal operation.

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501-09-18 Rear View Mirrors 501-09-18

REMOVAL AND INSTALLATION

Exterior Mirror (43 364 0)

REMOVAL AND INSTALLATION

Removal 4. Disconnect the mirror electrical connector.

1. Remove the exterior mirror trim panel.
1. Remove the screw cover.
2. Remove the retaining screw.

5. Remove the mirror retaining screws.

2. Disconnect the mirror control switch elec-

trical connector.

6. Remove the mirror.

3. Remove the front door trim panel. For

additional information, refer to Section
501-05.

Installation
1. To install, reverse the removal procedure.

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501-09-19 Rear View Mirrors 501-09-19

REMOVAL AND INSTALLATION

Auto-dimming Interior Mirror

3. Using a suitable wooden block and a soft
faced hammer, push the special tool up-
wards to release the locking tang.
Special Tool(s)
Remover, Interior Rear View
Mirror
501-090 (43-002)

Removal
1. Disconnect the auto-dimming interior mir-
ror electrical connector.

4. Remove the special tool.

• Loosen the retaining nut
5. CAUTION: Care must be taken when
removing the auto-dimming interior
mirror to prevent damage to the
windshield glass.
NOTE: Support the auto-dimming interior mirror.
Using a suitable wooden block and a soft
faced hammer, remove the auto-dimming
interior mirror.

2. Install the special tool to the auto-dimming

interior mirror.
• Tighten the retaining nut.

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501-09-20 Rear View Mirrors 501-09-20

REMOVAL AND INSTALLATION (Continued)

Installation
1. NOTE: Make sure the auto-dimming interior
mirror is correctly located.
Attach the auto-dimming interior mirror to
the mounting bracket.

2. Using a suitable wooden block and a soft

faced hammer, install the auto-dimming
interior mirror.
3. Connect the auto-dimming interior mirror
electrical connector.

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501-10-1 Seating 501-10-1

SECTION 501-10 Seating

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-10-2

DESCRIPTION AND OPERATION

Seats ................................................................................................................................. 501-10-3

Seat Position Sensor ........................................................................................................ 501-10-5
Occupant Classification Sensor........................................................................................ 501-10-5

DIAGNOSIS AND TESTING

Seats ................................................................................................................................. 501-10-6

Principals of Operation ..................................................................................................... 501-10-6
Inspection and Verification ............................................................................................... 501-10-6
Symptom Chart ................................................................................................................ 501-10-6
Pinpoint Tests .................................................................................................................. 501-10-7

REMOVAL AND INSTALLATION

Front Seat .................................................................................................... (40 100 0) 501-10-19

Front Seat Backrest........................................................................................................... 501-10-21
Front Seat Cushion....................................................................................... (40 104 0) 501-10-23
Rear Seat Backrest ...................................................................................... (40 128 0) 501-10-24
Rear Seat Backrest Latch............................................................................. (40 534 0) 501-10-26

DISASSEMBLY AND ASSEMBLY

Front Seat Cushion — 1.8L/2.0L/2.5L/2.0L Diesel ........................................ (40 104 0) 501-10-27

Front Seat Backrest — 1.8L/2.0L/2.5L/2.0L Diesel ....................................... (40 106 0) 501-10-28
Rear Seat Cushion — Vehicles With: Integrated Child Safety Seat ................................... 501-10-31
Rear Seat Backrest ...................................................................................... (40 127 0) 501-10-33

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SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Front seat retaining bolts 25 18 –
Front seat backrest retaining bolts 45 33 –
Front seat cushion retaining nuts 15 11 –
Front safety belt lower anchor retaining bolt 35 26 -
Rear seat backrest center hinge pin 20 15 –
Rear seat backrest hinge retaining bolts 55 41 –
Rear seat backrest retaining bolts (4 door) 25 18 –
Rear seat backrest center hinge locking plate re- 25 18 -
taining bolt (5 door and Wagon)
Rear seat backrest latch bolts 30 22 –
Rear center safety belt lower anchor and buckle 55 41 -
assembly retaining bolt
Rear seat cushion retaining bolts 25 18 –
Rear seat cushion integrated child safety seat re- 7 - 62
taining bolts

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DESCRIPTION AND OPERATION

Seats
DESCRIPTION AND OPERATION

adjustment. The eight-way power seat

Depending on vehicle specifications the driver
adjustment functions are controlled electrically.
seat can be equipped with two-way power seat
height adjustment or with eight-way power seat

Front Seat Active Head Restraint

together with a very hard wearing fabric tape. In

Both front seats are equipped with active head
the event of a rear collision the back of the
restraints that move forwards in the event of a
occupant presses against the fabric tape which
rear collision. The two supports of the head
then presses the upper part of the head restraint
restraints inside the seat backrest are joined
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DESCRIPTION AND OPERATION (Continued)

upwards and forwards by means of a pivot point. the head restraint returns to its initial position by
When the pressure of the occupant is released a spring mechanism.

Item Part Description

Item Part Description Number
Number
3 Head restraint electrical
1 Occupant classification sen- connector
sor (passenger seat only)
4 Video system harness
2 Head restraint with visual retaining clips
display screen

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DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
5 Seat position sensor (driver
seat only)
6 Under seat electrical con-
nector

The vehicle can be specified with a video system.

Visual display screens are fitted within the head
restraint. An electrical wiring harness within the
seat backrest carries the electrical signals from
the control unit to the display screens. This wiring
harness has a connector attached to the seat
cushion base and at the top of the backrest for
ease of servicing. If the display screen is
inoperative, a new head restraint must be
installed.

Seat Position Sensor

The seat position sensor is located on the driver
seat track. The seat position sensor determines
the position of the driver seat. For additional
information, refer to Section 501-20A / 501-20B.

Occupant Classification Sensor

NOTE: The occupant classification sensor is an
integral part of the passenger seat cushion and
cannot be serviced separately.
The occupant classification sensor detects, by
integrated pressure sensors, the presence of a
passenger or object on the seat cushion. For
additional information, refer to Section 501-20A /
501-20B.

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DIAGNOSIS AND TESTING

Seats
DIAGNOSIS AND TESTING

For Wiring Scematics and Connector Information, • Vertical adjustment of the front of the seat
refer to the Wiring Diagram Cell 501-10. cushion;
• Vertical adjustment of the rear of the seat
cushion;
Principals of Operation • Horizontal seat movement along the seat
The vehicle is equipped with a bi-directional track through a mechanical worm drive;
power operated driver seat as standard where • Seat backrest position adjustment of the
the power function is limited to seat height backrest rake angle.
adjustment only. Vehicles equipped with the full
eight-way power seat functionality are controlled
by a single multifunction control switch. In each Inspection and Verification
case the switch is mounted onto the seat base
panel within easy reach of the driver. 1. Verify the customer concern
2. Visually inspect for obvious signs of
Seats with power height adjustment retain
mechanical or electrical damage.
manual adjustment controls to attain seat
adjustment. The bi-directional switch controls the
operation of a single motor which depending on Visual Inspection Chart
switch operation will either raise or lower the seat Mechanical Electrical
height through a series of mechanical linkages. Damaged switch(es). Fuse(s).
Wiring harness
Seats with full eight-way adjustment are able to
Electrical connector(s).
adjust the seat position through any one of four
Motor(s).
different motors. Each seat function is controlled
Switch(es).
by a single multifunction switch, which in turn
controls the operation of the bi-directional motor 3. If an obvious cause for an observed or
of the selected adjustment feature to achieve: 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.
Symptom Chart

Condition Possible Sources Action

• The power seat is inoperative • Seat control switch. • CARRY OUT the Seat Control
Switch Component Test.
REFER to the Wiring Diagrams.
• Circuit(s). • GO to Pinpoint Test A
• Motor(s).
• The power seat does not move • Seat control switch. • CARRY OUT the Seat Control
horizontally Switch Component Test.
REFER to the Wiring Diagrams.
• Circuit(s). • GO to Pinpoint Test B
• Motor(s).
• The power seat does not move • Seat control switch. • CARRY OUT the Seat Control
vertically Switch Component Test.
REFER to the Wiring Diagrams.

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DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• Circuit(s). • GO to Pinpoint Test C
• Motor(s)
• The power seat does not recline • Seat control switch. • CARRY OUT the Seat Control
Switch Component Test.
REFER to the Wiring Diagrams.
• Circuit. • GO to Pinpoint Test D
• Motor.
• The heated seat is inoperative • Heated seat control switch(es). • CARRY OUT the Heated Seat
Control Switch Component Test.
REFER to the Wiring Diagrams.
• Circuit(s). • GO to Pinpoint Test E

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE VOLTAGE TO THE POWER SEAT SWITCH CIRCUIT 29-AH35 (OG/YE)
1 Disconnect Inoperative power seat control
switch.
2 Key in ON position.
3 Measure the voltage between the power seat
control switch C60 pin 15, circuit 29-AH35
(OG/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A2
→ No
REPAIR circuit 29-AH35 (OG/YE). TEST
the system for normal operation.
A2: CHECK THE POWER SEAT SWITCH GROUND CIRCUIT 31-AH35 (BK) FOR CONTINUITY
1 Key in OFF position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the power
seat control switch C60 pin 16, circuit 31-AH35
(BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
Eight-way power seat, INSTALL a new
power seat control switch. Two-Way power
seat, INSTALL a new power seat control
switch and motor.
→ No
REPAIR circuit 31-AH35 (BK). TEST the
system for normal operation.
PINPOINT TEST B: THE POWER SEAT DOES NOT MOVE HORIZONTALLY
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE REARWARD VOLTAGE TO THE SEAT HORIZONTAL MOVEMENT MOTOR
1 Key in OFF position.
2 Detach the seat assembly from the floor.
3 Disconnect C467 Power seat horizontal motor.
4 Key in ON position.
5 Operate the power seat horizontal control
switch to the REARWARD position.
6 Measure the voltage between the power seat
horizontal control switch C467 pin 1, circuit 33-
AH9 (YE/GN), harness side and ground.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the voltage greater than 10 volts?

→ Yes
GO to B2
→ Yes
REPAIR circuit 33-AH9 (YE/GN). TEST the
system for normal operation.
B2: CHECK THE FORWARD VOLTAGE TO THE SEAT HORIZONTAL MOVEMENT MOTOR
1 Operate the power seat horizontal control
switch to the FORWARD position.
2 Measure the voltage between the power seat
horizontal control switch C467 pin 4, circuit 32-
AH9 (WH/GN), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new seat horizontal movement
motor. TEST the system for normal opera-
tion.
→ No
REPAIR circuit 32-AH9 (WH/GN). TEST the
system for normal operation.

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DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: THE POWER SEAT DOES NOT MOVE VERTICALLY
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE DOWN VOLTAGE TO THE SEAT FRONT HEIGHT MOVEMENT MOTOR
NOTE: If the front seat height motor is inoperative GO to C1, if the rear seat height motor is inoperative
GO to C3.
1 Key in OFF position.
2 1. Detach the seat assembly from the floor.
3 Disconnect C467 Power seat front height mo-
tor.
4 Key in ON position.
5 Operate the power seat front height control
switch to the DOWN position.
6 Measure the voltage between the power seat
front height control switch C467 pin 3, circuit
33-AH10 (YE/BK), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to C4
→ No
REPAIR circuit 33-AH10 (YE/BK). TEST the
system for normal operation.
C2: CHECK THE UP VOLTAGE TO THE SEAT FRONT HEIGHT MOVEMENT MOTOR
1 Operate the power seat front height control
switch to the UP position.
2 Measure the voltage between the power seat
front height control switch C467 pin 6, circuit
32-AH10 (WH/BK), harness side and ground.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new seat front height movement
motor. TEST the system for normal opera-
tion.
→ No
REPAIR circuit 32-AH10 (WH/BK). TEST
the system for normal operation.
C3: CHECK THE DOWN VOLTAGE TO THE SEAT REAR HEIGHT MOVEMENT MOTOR
1 Key in OFF position.
2 1. Detach the seat assembly from the floor.
3 Disconnect C467 Power seat rear height mo-
tor.
4 Key in ON position.
5 Operate the power seat rear height control
switch to the DOWN position.
6 Measure the voltage between the power seat
rear height control switch C467 pin 2, circuit
33-AH11 (YE/VT), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
C6 doesn't exist.
→ No

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 33-AH11 (YE/VT). TEST the
system for normal operation.
C4: CHECK THE UP VOLTAGE TO THE SEAT REAR HEIGHT MOVEMENT MOTOR
1 Operate the power seat rear height control
switch in the UP position.
2 Measure the voltage between the power seat
rear height control switch C467 pin 5, circuit
32-AH11 (WH/VT), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new seat rear height movement
motor. TEST the system for normal opera-
tion.
→ No
REPAIR circuit 32-AH11 (WH/VT). TEST
the system for normal operation.
PINPOINT TEST D: THE POWER SEAT DOES NOT RECLINE
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE REARWARD VOLTAGE TO THE SEAT BACKREST MOVEMENT MOTOR
1 Key in OFF position.
2 Detach the seat assembly from the floor.
3 Disconnect .
4 Key in ON position.
5 C463 Power seat backrest motor
6 Operate the power seat rear backrest control
switch to the REARWARD position.
7 Measure the voltage between the power seat
rear height control switch C463 pin 1, circuit
33-AH7 (YE/RD), harness side and ground.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the voltage greater than 10 volts?

→ Yes
GO to D2
→ No
REPAIR circuit 33-AH7 (YE/RD). TEST the
system for normal operation.
D2: CHECK THE FORWARD VOLTAGE TO THE SEAT BACKREST MOVEMENT MOTOR
1 Operate the power seat backrest control switch
in the FORWARD position.
2 Measure the voltage between the power seat
rear height control switch C463 pin 2, circuit
32-AH7 (WH/RD), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
INSTALL a new seat backrest movement
motor. TEST the system for normal opera-
tion.
→ No
REPAIR circuit 32-AH7 (WH/RD). TEST the
system for normal operation.

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DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E: THE HEATED SEAT IS INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK FOR VOLTAGE TO THE HEATED SEAT CONTROL SWITCH
1 Key in ON position.
2 Operate the heated seat control switch.
• Does the yellow heated seat control switch
LED illuminate?
→ Yes
GO to E2
→ No
GO to E7
E2: CHECK FOR VOLTAGE TO THE INOPERATIVE HEATED SEAT
1 Key in OFF position.
2 Disconnect Inoperative heated seat C60 or
C61.
3 Key in ON position.
4 Operate the heated seat control switch.
5 Measure the voltage between:
NOTE: LHD Driver Side Heated Seat
- the heated seat cushion C60 pin 9, circuit
15S-HC6 (GN/YE) harness side and ground.
NOTE: LHD Passenger Side Heated Seat
- the heated seat cushion C61 pin 9, circuit
15S-HC9 (GN/BK) harness side and ground.
NOTE: RHD Driver Side Heated Seat
- the heated seat cushion C60 pin 9, circuit
15S-HC9 (GN/BK) harness side and ground.
NOTE: RHD Passenger Side Heated Seat
- the heated seat cushion C61 pin 9, circuit
15S-HC6 (GN/YE) harness side and ground.
• Is the voltage greater than 10 volts?
→ Yes
GO to E3
→ No
REPAIR circuit 15S-HC6 (GN/YE) left front
seat or circuit 15S-HC9 (GN/BK) right front
seat. TEST the system for normal operation.
E3: CHECK THE INOPERATIVE HEATED SEAT GROUND CIRCUIT
1 Key in OFF position.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 1. Measure the resistance between:
NOTE: LHD Driver Side Heated Seat
- the heated seat backrest C60 pin 18, circuit
31-HC7 (BK) harness side and ground.
NOTE: LHD Passenger Side Heated Seat
- the heated seat cushion C61 pin 18, circuit
31-HC18 (BK) harness side and ground.
NOTE: RHD Driver Side Heated Seat
- the heated seat cushion C60 pin 18, circuit
31-HC18 (BK) harness side and ground.
NOTE: RHD Passenger Side Heated Seat
- the heated seat backrest C61 pin 18, circuit
31-HC7 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to E4
→ No
REPAIR circuit 31-HC7 (BK) left front seat
or circuit 31-HC10 (BK) right front seat.
TEST the system for normal operation.
E4: CHECK FOR CONTINUITY BETWEEN THE BACKREST AND CUSHION HEATER MATS
1 Measure the resistance between
NOTE: LHD Driver Side Heated Seat
- the heated seat C60 pins 10 and 17, circuit
15S-HC7 (GN/BU) harness side.
NOTE: LHD Passenger Side Heated Seat
- the heated seat C61 pins 10 and 17, circuit
15S-HC10 (GN/OG) harness side.
NOTE: RHD Driver Side Heated Seat
- the heated seat C61 pins 10 and 17, circuit
15S-HC10 (GN/OG) harness side.
NOTE: RHD Passenger Side Heated Seat
- the heated seat C60 pins 10 and 17, circuit
15S-HC7 (GN/BU) harness side.

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 5 ohms?

→ Yes
GO to E5
REPAIR circuit 15S-HC7 (GN/BU) left front
seat or circuit 15S-HC10 (GN/OG) right front
seat). TEST the system for normal opera-
tion.
E5: CHECK THE HEATED SEAT BACKREST HEATER MAT FOR CONTINUITY
1 Measure the resistance between:
NOTE: LHD Driver Side Heated Seat
- the heated seat backrest C60h pins 1 and 2,
circuit 31-HC7 (BK) component side.
NOTE: LHD Passenger Side Heated Seat
- the heated seat backrest C61h pins 1 and 2,
circuit 31-HC10 (BK) component side.
NOTE: RHD Driver Side Heated Seat
- the heated seat backrest C61h pins 1 and 2,
circuit 31-HC10 (BK) component side.
NOTE: RHD Passenger Side Heated Seat
- the heated seat backrest C60h pins 1 and 2,
circuit 31-HC7 (BK) component side

• Is the resistance less than 9 ohms?

→ Yes
GO to E6

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
INSTALL a new heated seat backrest heater
mat. TEST the system for normal operation.
E6: CHECK THE HEATED SEAT CUSHION HEATER MAT FOR CONTINUITY
1 Disconnect 1. C60d Heated seat cushion
heater Graphic C60d pin 1 to pin 2 - ohms.
2 Measure the resistance between:
NOTE: LHD Driver Side Heated Seat
- the heated seat backrest C60d pins 1 and 2,
circuit 15S-HC6 (GN/YE) component side.
NOTE: LHD Passenger Side Heated Seat
- the heated seat backrest C61d pins 1 and 2,
circuit 15S-HC9 (GN/BK) component side.
NOTE: RHD Driver Side Heated Seat
- the heated seat backrest C61d pins 1 and 2,
circuit 15S-HC9 (GN/BK) component side.
NOTE: RHD Passenger Side Heated Seat
- the heated seat backrest C60d pins 1 and 2,
circuit 15S-HC6 (GN/YE) component side.

• Is the resistance less than 9 ohms?

→ Yes
VERIFY the customer concern.
→ No
INSTALL a new heated seat cushion heater
mat. TEST the system for normal operation.
E7: CHECK FOR IGNITION VOLTAGE TO THE HEATED SEAT CONTROL SWITCH
1 Operate the vehicle light switch.
• Does the heated seat control switch green LED
illuminate?
→ Yes
REPAIR circuit 15-HC6 (GN/YE) left front
seat or circuit 15-HC9 (GN/BK) right front
seat. TEST the system for normal operation.
→ No
GO to E8

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DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
E8: CHECK FOR SWITCH VOLTAGE TO THE HEATED SEAT CONTROL SWITCH
1 Key in OFF position.
2 Disconnect Inoperative heated seat control
switch.
3 Key in ON position.
4 Measure the voltage between the inoperative
heated seat control switch C471 pin 8, circuit
64S-LH29 (BU) (C472 circuit 64S-LH43
[BU/RD] right front seat), harness side and
ground.

• Is the voltage greater than 10 volts?

→ Yes
REPAIR circuit 31-LH29 (BK) left front seat
or circuit 31-LH43 (BK) right front seat.
TEST the system for normal operation.
→ No
REPAIR circuit 64S-LH29 (BU) (circuit 64S-
LH43 [BU/RD] right front seat). TEST the
system for normal operation.

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REMOVAL AND INSTALLATION

Front Seat (40 100 0)

REMOVAL AND INSTALLATION

Removal 6. Detach the safety belt lower anchor from

the underside of the seat.
WARNING: To avoid accidental
deployment the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Move the seat fully rearwards. 7. Remove the seat rear retaining bolt covers.
3. Disconnect the underseat electrical con-
nector and video system electrical connec-
tor (if equipped).

8. Remove the seat rear retaining bolts and

remove the seat.

4. Remove the seat front retaining bolts.

5. Move the seat fully forwards.

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501-10-20 Seating 501-10-20

REMOVAL AND INSTALLATION (Continued)

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-10-21 Seating 501-10-21

REMOVAL AND INSTALLATION

Front Seat Backrest

Removal
1. Remove the front seat. For additional 5. Remove the inner side trim panel.
information, refer to Front Seat in this 1. Detach the wiring harness retaining clip.
section. 2. Remove the trim panel retaining screw.
2. Remove the backrest recliner handwheel 3. Detach the trim panel retaining clip.
(if equipped).

6. Detach the side air bag module electrical

3. Partially detach the outer side trim panel. connector from the underside of the seat.
• Remove the screws. • Detach the clips.
• Detach the electrical connector.

4. Remove the outer side trim panel.

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REMOVAL AND INSTALLATION (Continued)

7. Detach the backrest heater mat electrical Installation
connector from the underside of the seat
(if equipped). 1. To install, reverse the removal procedure.
• Detach the clips.
• Detach the electrical connector.

8. Detach the video system connector from

the underside of the seat (if equipped).
• Detach the clips.
• Detach the electrical connector.

9. Remove the front seat backrest.

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501-10-23 Seating 501-10-23

REMOVAL AND INSTALLATION

Front Seat Cushion (40 104 0)

Removal Passenger seat

5. Remove the seat electrical connector
All vehicles mounting bracket.
1. Remove the front seat. For additional
1. Disconnect the occupant classification
information, refer to Front Seat in this
sensor electrical connector from the
section.
underseat connector.
Driver and passenger seat
2. Detach the underseat connector from the
2. Detach the cushion heater mat electrical
underside of the seat.
connector (if equipped).
3. Drill out the rivets.
• Cut the cable tie.
• Disconnect the electrical connector.

Driver and passenger seat

6. Remove the front seat cushion.
3. Detach the video system electrical connec-
1. Disconnect the seat height adjust motor
tor (if equipped).
electrical connector.
2. Detach the wiring harness retaining clips.
3. Remove the nuts.

4. Adjust the backrest to the fully upright

position.

Installation
1. To install, reverse the removal procedure.

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501-10-24 Seating 501-10-24

REMOVAL AND INSTALLATION

Rear Seat Backrest (40 128 0)

Removal 4. Detach the rear center safety belt buckle.

4-door and wagon
1. NOTE: Remove and discard the retaining
clips.
Remove the rear seat cushion.
• Raise the front edge of the rear seat cush-
ion.

4-door
5. Remove the rear seat backrest.

5-door
2. Raise the rear edge of the rear seat
cushion.
All vehicles
3. CAUTION: Make sure a webbing
retainer is fitted at least 200 mm
towards the safety belt retractor from
the webbing stop.
Install the safety belt webbing retainer. 5-door and wagon
6. Fold the rear seat backrest forwards.
7. Remove the rear seat backrest center
hinge locking plate.
• Remove the rear seat backrest center
hinge locking plate retaining bolt.

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REMOVAL AND INSTALLATION (Continued)

8. NOTE: Remove and discard the rear seat

backrest outer hinge retaining clip.
Remove the rear seat backrest.

Installation
1. CAUTION: Check for correct operation
of the center safety belt retractor.
NOTE: Install new retaining clips.
To install, reverse the removal procedure.

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501-10-26 Seating 501-10-26

REMOVAL AND INSTALLATION

Rear Seat Backrest Latch (40 534 0)

Removal 4. Remove the rear seat backrest latch.

1. Disassemble the rear seat backrest. For
additional information, refer to Rear Seat
Backrest in this section.
2. Lock the rear seat backrest latch.

Installation
1. CAUTION: Check the backrest latch
3. NOTE: To aid installation, note the backrest cable routing, and the operation of the
latch cable position on the safety belt retractor. safety belt retractor and interlock
before fully assembling the rear seat
Detach the backrest latch cable from the backrest.
safety belt retractor.
To install, reverse the removal procedure.

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501-10-27 Seating 501-10-27

DISASSEMBLY AND ASSEMBLY

Front Seat Cushion — 1.8L/2.0L/2.5L/2.0L Diesel (40 104 0)

DISASSEMBLY AND ASSEMBLY

Disassembly
1. NOTE: The occupant classification sensor is Assembly
an integral part of the passenger seat cushion
and cannot be serviced separately. If the 1. NOTE: Use hog ring pliers to close the hog
occupant classification sensor is found to be rings. Do not use any other tool. The hog rings
unserviceable, following the correct diagnosis must be closed to overlap as illustrated.
and testing, a new passenger seat cushion To assemble, reverse the disassembly
must be installed. procedure.
Detach the cushion cover from the
underside of the seat.
• Detach the retaining strips.

2. Remove the cushion and heater mat (if

equipped)from the seat base.
3. Remove the cushion cover.
1. Roll the cushion cover back to access the
pleating hog rings.
2. Cut the hog rings.

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501-10-28 Seating 501-10-28

DISASSEMBLY AND ASSEMBLY

Front Seat Backrest — 1.8L/2.0L/2.5L/2.0L Diesel (40 106 0)

Disassembly 4. Detach the backrest cover tensioning

cords from the backrest.
1. Remove the head restraint.
• Detach the video system electrical connec-
tor (if equipped).

5. Detach the backrest vertical retaining

strips from the backrest frame.
2. Remove the backrest lumbar support
adjust handwheel (if equipped).
3. Detach the backrest cover from the
underside of the backrest.
• Detach the retaining strip.

6. Detach the backrest recline motor wiring

harness from the backrest (if equipped).
• Disconnect the electrical connector.
• Detach the clips.

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501-10-29 Seating 501-10-29

DISASSEMBLY AND ASSEMBLY (Continued)

7. Roll the backrest cover up the backrest. 9. WARNING: To minimize the possibility
of injury in the event of premature
deployment, always carry a live air
bag module with the bag and trim
cover pointed away from the body.
Failure to follow this instruction may
result in personal injury
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury
NOTE: To aid installation, note the position of the
8. WARNING: Always wear safety glasses ground cable attached to the side air bag module
when working on an air bag equipped lower retaining screw and the locating tangs on
vehicle and when handling an air bag the rear of side air bag module.
module. Failure to follow this Remove the side air bag module.
instruction may result in personal
injury
Disconnect the side air bag module elec-
trical connector.

10. Remove the head restraint guides.

• Using a suitable screwdriver, depress the
locking tang.

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501-10-30 Seating 501-10-30

DISASSEMBLY AND ASSEMBLY (Continued)

11. Detach the backrest cover upper retain- 15. Remove the lumbar support.
ing strip from the backrest.

12. Detach the backrest cover tensioning Assembly

cords from the backrest.
1. To assemble, reverse the disassembly
procedure.

13. Remove the backrest cover.

14. Detach the lumbar support adjuster from
the backrest.

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501-10-31 Seating 501-10-31

DISASSEMBLY AND ASSEMBLY

Rear Seat Cushion — Vehicles With: Integrated Child Safety Seat

Disassembly 2. Remove the integrated child safety seat.

1. CAUTION: The integrated child safety • Remove the retaining clips.
seats have a warning label, which is
sewn to the cushion cover and
attached to the safety seat cushion
frame with clips.
Detach the integrated child safety seats
from the cushion frame.

3. NOTE: Note the position of the hog rings, to

aid installation.
Detach the cushion cover and carpet from
the underside of the seat.
• Cut the hog rings.

4. Remove the cushion cover.

1. Roll the cushion cover inwards to access
the pleating hog rings.
2. Cut the hog rings.

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501-10-32 Seating 501-10-32

DISASSEMBLY AND ASSEMBLY (Continued)

Assembly
1. NOTE: Use hog ring pliers to close the hog
rings. Do not use any other tool. The hog rings
must be closed to overlap as illustrated.
To assemble, reverse the disassembly
procedure.

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501-10-33 Seating 501-10-33

DISASSEMBLY AND ASSEMBLY

Rear Seat Backrest (40 127 0)

Disassembly 4. NOTE: The locking tang releases in the

opposite direction for inner and outer head
1. Remove the head restraint(s).
restraint guides.
2. Remove the armrest.
Remove the outer head restraint guides.
1. Release the retaining clips.
1. Using a suitable screwdriver, depress the
2. Slide the retaining clips forwards.
locking tang.
2. Pull the guide upwards.

3. Remove the backrest center hinge pin.

• Remove and discard the pin.
5. Detach the backrest cover from the
backrest.
• Detach the retaining strip.

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501-10-34 Seating 501-10-34

DISASSEMBLY AND ASSEMBLY (Continued)

6. Detach the backrest cover from the back- 9. Detach the backrest cover from the
rest release button. armrest mounting.
1. Roll the backrest cover inwards to access
the retaining strips.
2. Detach the retaining strips.

7. Remove the safety belt webbing trim

panel.

10. Remove the center head restraint guides.

1. From the underside of the rear seat
backrest, depress the locking tang.
2. Slide the head restraint guides upwards
through the backrest cover.

8. Detach the backrest cover from the

underside of the armrest mounting
bracket.
• Detach the retaining strip.

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501-10-35 Seating 501-10-35

DISASSEMBLY AND ASSEMBLY (Continued)

Assembly
11. CAUTION: When removing the 1. WARNING: If the safety belt webbing
backrest cover take care not to detach retracts further than the stop on the
the webbing retainer. webbing, a new safety belt retractor
Remove the backrest cover. must be installed.
1. Roll the backrest cover inwards to access CAUTION: Make sure the webbing
the pleating hog rings. retainer is fitted at least 200 mm from the
2. Cut the hog rings. webbing stop towards the retractor.
• Feed the safety belt webbing through the NOTE: Use hog ring pliers to close the hog rings.
backrest cover. Do not use any other tool. The hog rings must be
closed to overlap as illustrated.
NOTE: Use new hinge pins.
To assemble, reverse the disassembly
procedure.

12. Remove the rear seat backrest.

• Feed the safety belt webbing through the
backrest.
13. Remove the rear seat backrest latch.
For additional information, refer to
Backrest Latch in this section.
14. Remove the center safety belt retractor.
For additional information, refer to
Section 501-20A / 501-20B.

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501-11-1 Glass, Frames and Mechanisms 501-11-1

SECTION 501-11 Glass, Frames and Mechanisms

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-11-2

DIAGNOSIS AND TESTING

Glass, Frames and Mechanisms ....................................................................................... 501-11-3

Inspection and Verification ............................................................................................... 501-11-3
Symptom Chart ................................................................................................................ 501-11-3
Pinpoint Tests .................................................................................................................. 501-11-4

GENERAL PROCEDURES

Door Window Motor Initialization ....................................................................................... 501-11-28

REMOVAL AND INSTALLATION

Front Door Window Glass............................................................................. (42 314 0) 501-11-29

Rear Door Window Glass ............................................................................. (42 315 0) 501-11-31
Rear Quarter Window Glass — 4-Door/5-Door............................................. (42 514 0) 501-11-34
Rear Quarter Window Glass — Wagon ........................................................ (42 514 0) 501-11-38
Rear Window Glass — 4-Door........................................................................................... 501-11-41
Rear Window Glass — 5-Door........................................................................................... 501-11-46
Rear Window Glass — Wagon .......................................................................................... 501-11-51
Windshield Glass.......................................................................................... (42 115 0) 501-11-55
Front Door Window Regulator and Motor ..................................................... (42 338 0) 501-11-60
Rear Door Window Regulator ....................................................................... (42 338 0) 501-11-62
Rear Door Window Regulator and Motor ...................................................... (42 338 0) 501-11-63

08/2002 2003.0 Mondeo

501-11-2 Glass, Frames and Mechanisms 501-11-2

SPECIFICATIONS

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Cleaner/activator 99-SX-M2G342-BA
Primer 99-SX-M2G343-AA
2K Adhesive 99-SX-M2G322-AA
2K Hardener/mixer 99-SX-M2G322-BA

Torque Specifications
Description Nm lb-ft lb-in
Door window regulator retaining bolts 7 – 62
Door window glass clamp retaining bolts 7 – 62
Windshield wiper arm retaining nut 15 11 –
Rear window wiper arm retaining nut 14 10 –
Rear window wiper motor retaining bolts 8 – 71

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501-11-3 Glass, Frames and Mechanisms 501-11-3

DIAGNOSIS AND TESTING

Glass, Frames and Mechanisms

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 501-11 for Mechanical Electrical

schematic and connector information. Window seal Fuse(s)
Door window frame Electrical connector(s)
Switch(es)
Inspection and Verification Circuit(s)
1. Verify the customer concern. Initialization process
2. Visually inspect for obvious signs of 3. If an obvious cause for an observed or
mechanical or electrical damage. reported concern is found, correct the cause
(if possible) before proceeding to the next
Visual Inspection Chart step.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• A single power window is inop- • Driver power window control • CARRY OUT the Driver Power
erative - front and rear power switch. Window Control Switch Compo-
windows - driver power window nent Test. REFER to the Wiring
Diagrams.
• Circuit(s). • GO to Pinpoint Test A
• A single power window is inop- • Inoperative power window con- • CARRY OUT the Power Win-
erative - front and rear power trol switch. dow Control Switch Component
windows - front passenger Test. REFER to the Wiring Dia-
power window grams.
• Driver power window control • CARRY OUT the Driver Power
switch. Window Control Switch Compo-
nent Test. REFER to the Wiring
Diagrams.
• Circuit(s). • GO to Pinpoint Test B
• A single power window is inop- • Inoperative power window con- • CARRY OUT the Power Win-
erative - front and rear power trol switch. dow Control Switch Component
windows - rear passenger power Test. REFER to the Wiring Dia-
window grams.
• Driver power window control • CARRY OUT the Driver Power
switch. Window Control Switch Compo-
nent Test. REFER to the Wiring
Diagrams.
• Circuit(s). • GO to Pinpoint Test C
• The one-touch up/down feature • Driver power window control • CARRY OUT the Driver Power
is inoperative - front and rear switch. Window Control Switch Compo-
power windows nent Test. REFER to the Wiring
Diagrams.
• Inoperative power window con- • CARRY OUT the Power Win-
trol switch. dow Control Switch Component
Test. REFER to the Wiring Dia-
grams.

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501-11-4 Glass, Frames and Mechanisms 501-11-4

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Power window motor. • INSTALL a new power window
motor. REFER to Section 501-
11.
• Global closing is inoperative • Generic electronic module • For additional information,
(GEM). REFER to WDS.
• Circuit(s).
• A single power window is inop- • Driver power window control • CARRY OUT the Driver Power
erative - driver side switch. Window Control Switch Compo-
nent Test. REFER to the Wiring
Diagrams.
• Driver power window motor. • GO to Pinpoint Test D
• Circuit(s).
• A single power window is inop- • Passenger power window con- • CARRY OUT the Passenger
erative - passenger side trol switch. Power Window Control Switch
Component Test. REFER to the
Wiring Diagrams.
• Passenger power window • GO to Pinpoint Test E
motor.
• Circuit(s).
• The one-touch up/down feature • Power window control switch. • CARRY OUT the Power Win-
is inoperative - front power win- dow Control Switch Component
dows Test. REFER to the Wiring Dia-
grams.
• The defrost system is inopera- • Generic electronic module • For additional information,
tive (GEM). REFER to WDS.
• Heated windshield relay.
• Heated windshield control
switch.
• Heated rear window relay.
• Heated rear window control
switch.
• Heated rear window grid wire.
• Circuit(s).
• The defrost system will not shut • Central timer module. • For additional information,
off automatically • Heated windshield relay. REFER to WDS.
• Heated rear window relay.

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: A SINGLE POWER WINDOW IS INOPERATIVE - FRONT AND REAR POWER
WINDOWS - DRIVER POWER WINDOW
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
1 Key in ON position.

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501-11-5 Glass, Frames and Mechanisms 501-11-5

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the driver power window control switch

LED illuminate?
→ Yes
GO to A2
→ No
GO to A7
A2: CHECK FOR BATTERY VOLTAGE TO THE DRIVER POWER WINDOW MOTOR
1 Key in OFF position.
2 Disconnect Driver Power Window Motor C705.
3 Key in ON position.
4 Measure the voltage between the driver power
window motor C705 pin 7, circuit 29-AJ26
(OG/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A3
→ No
REPAIR circuit 29-AJ26 (OG/YE). TEST the
system for normal operation.
A3: CHECK FOR IGNITION VOLTAGE TO THE DRIVER POWER WINDOW MOTOR
1 Measure the voltage between the driver power
window motor C705 pin 2, circuit 15-AJ26A
(GN/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A4
→ No
REPAIR circuit 15-AJ26A (GN/YE). TEST
the system for normal operation.

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501-11-6 Glass, Frames and Mechanisms 501-11-6

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
A4: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW MOTOR AND
GROUND
1 Key in OFF position.
2 Measure the resistance between the driver
power window motor C705 pin 8, circuit 31-
AJ26 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A5
→ No
REPAIR circuit 31-AJ26 (BK). TEST the
system for normal operation.
A5: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW MOTOR DOWN
CIRCUIT AND GROUND
1 Operate and hold the driver power window mo-
tor control switch in the DOWN position.
2 Measure the resistance between the driver
power window motor C705 pin 4, circuit 31S-
AJ40 (BK/GN) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A6
→ No
REPAIR circuit 31S-AJ40 (BK/GN). TEST
the system for normal operation.
A6: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW MOTOR UP CIRCUIT
AND GROUND
1 Operate and hold the driver power window mo-
tor control switch in the UP position.

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501-11-7 Glass, Frames and Mechanisms 501-11-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the driver
power window motor C705 pin 3, circuit 31S-
AJ41 (BK/RD) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new power window motor.
REFER to the procedure in this Section:
Door Window Regulator and Motor. TEST
the system for normal operation.
→ No
REPAIR circuit 31S-AJ41 (BK/RD). TEST
the system for normal operation.
A7: CHECK THE DRIVER POWER WINDOW CONTROL SWITCH GROUND CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Power Window Control
Switch C709.
3 Measure the resistance between the driver
power window control switch C709 pin 4, circuit
31-AJ7 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to A8
→ No
REPAIR circuit 31-AJ7 (BK). TEST the sys-
tem for normal operation.
A8: CHECK FOR IGNITION VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
1 Key in ON position.

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501-11-8 Glass, Frames and Mechanisms 501-11-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the driver power
window control switch C709 pin 13, circuit 15-
LH14 (GN/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 15-LH14 (GN/YE). TEST the
system for normal operation.
PINPOINT TEST B: A SINGLE POWER WINDOW IS INOPERATIVE - FRONT AND REAR POWER
WINDOWS - FRONT PASSENGER POWER WINDOW
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE INOPERATIVE WINDOW FOR OPERATION FROM THE DRIVER POWER
WINDOW CONTROL SWITCH
1 Key in ON position.
2 Operate the driver power window control
switch.
• Does the front passenger power window oper-
ate correctly?
→ Yes
GO to B2
→ No
GO to B4
B2: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH AND THE MOTOR DOWN CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Power Window Control
Switch C709.
3 Disconnect Passenger Power Window Control
Switch C710.

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501-11-9 Glass, Frames and Mechanisms 501-11-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
NOTE: Left-hand Drive Front Passenger Power
Window
- the front passenger power window control
switch C710 pin 2, circuit 31S-AJ54B
(BK/GN) harness side and the driver power
window control switch C709 pin 14, circuit
31S-AJ54 (BK/GN) harness side.
NOTE: Right-hand Drive Front Passenger Power
Window
- the front passenger power window control
switch C710 pin 2, circuit 31S-AJ54B
(BK/GN) harness side and the driver power
window control switch C709 pin 6, circuit 31S-
AJ54 (BK/GN) harness side.
• Is the resistance less than 5 ohms?
→ Yes
GO to B3
→ No
REPAIR circuit 31S-AJ54B (BK/GN). TEST
the system for normal operation.
B3: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH AND THE MOTOR UP CIRCUIT
1 Measure the resistance between:
NOTE: Left-hand Drive Front Passenger Power
Window
- the front passenger power window control
switch C710 pin 5, circuit 31S-AJ55B
(BK/RD) harness side and the driver power
window control switch C709 pin 15, circuit
31S-AJ55 (BK/RD) harness side.
NOTE: Right-hand Drive Front Passenger Power
Window
- the front passenger power window control
switch C710 pin 5, circuit 31S-AJ55B
(BK/RD) harness side and the driver power
window control switch C709 pin 7, circuit 31S-
AJ55 (BK/RD) harness side.
• Is the resistance less than 5 ohms?
→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 31S-AJ55B (BK/RD). TEST
the system for normal operation.
B4: CHECK FOR VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW CONTROL
SWITCH
1 Key in ON position.
• Does the front passenger power window con-
trol switch LED illuminate?
→ Yes

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501-11-10 Glass, Frames and Mechanisms 501-11-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to B5
→ No
GO to B10
B5: CHECK FOR BATTERY VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR
1 Key in OFF position.
2 Disconnect Passenger Power Window Motor
C706.
3 Key in ON position.
4 Measure the voltage between the passenger
power window motor C706 pin 7, circuit 29-
AJ27 (OG/WH) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to B6
→ No
REPAIR circuit 29-AJ27 (OG/WH). TEST
the system for normal operation.
B6: CHECK FOR IGNITION VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR
1 Measure the voltage between the passenger
power window motor C706 pin 2, circuit 15-
AJ27A (GN/WH) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to B7
→ No
REPAIR circuit 15-AJ27A (GN/WH). TEST
the system for normal operation.

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501-11-11 Glass, Frames and Mechanisms 501-11-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B7: CHECK THE INOPERATIVE PASSENGER POWER WINDOW MOTOR GROUND CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the passen-
ger power window motor C706 pin 8, circuit 31-
AJ27 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to B8
→ No
REPAIR circuit 31-AJ27 (BK). TEST the
system for normal operation.
B8: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR DOWN CIRCUIT AND GROUND
1 Operate and hold the inoperative passenger
power window motor control switch in the
DOWN position.
2 Measure the resistance between the passen-
ger power window motor C706 pin 4, circuit
31S-AJ54A (BK/GN) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to B9
→ No
REPAIR circuit 31S-AJ54A (BK/GN). TEST
the system for normal operation.

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501-11-12 Glass, Frames and Mechanisms 501-11-12

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B9: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR UP CIRCUIT AND GROUND
1 Operate and hold the inoperative passenger
power window motor control switch in the UP
position.
2 Measure the resistance between the passen-
ger power window motor C706 pin 3, circuit
31S-AJ55A (BK/RD) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new power window motor.
REFER to the procedure in this Section:
Door Window Regulator and Motor. TEST
the system for normal operation.
→ No
REPAIR circuit 31S-AJ55A (BK/RD). TEST
the system for normal operation.
B10: CHECK THE INOPERATIVE PASSENGER POWER WINDOW CONTROL SWITCH GROUND
CIRCUIT
1 Key in OFF position.
2 Disconnect Passenger Power Window Control
Switch C710.
3 Measure the resistance between the passen-
ger power window control switch C710 pin 6,
circuit 31-AJ18 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to B11
→ No

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501-11-13 Glass, Frames and Mechanisms 501-11-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 31-AJ18 (BK). TEST the
system for normal operation.
B11: CHECK FOR IGNITION VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH
1 Key in ON position.
2 Measure the voltage between the passenger
power window control switch C710 pin 1, circuit
15-LH31 (GN/BU) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 15-LH31 (GN/BU). TEST the
system for normal operation.
PINPOINT TEST C: A SINGLE POWER WINDOW IS INOPERATIVE - FRONT AND REAR POWER
WINDOWS - REAR PASSENGER POWER WINDOW
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE INOPERATIVE WINDOW FOR OPERATION FROM THE DRIVER POWER
WINDOW CONTROL SWITCH
1 Key in ON position.
2 Operate the driver power window control
switch.
• Does the inoperative rear passenger power
window operate correctly?
→ Yes
GO to C2
→ No
GO to C4
C2: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH AND THE MOTOR DOWN CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Power Window Control
Switch C709.
3 Disconnect Inoperative Passenger Power Win-
dow Control Switch C711 or C712.

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501-11-14 Glass, Frames and Mechanisms 501-11-14

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
NOTE: Left-hand Rear Passenger Power Window
- the driver power window control switch C709
pin 2, circuit 31S-AJ57 (BK/BU) harness side
and the left-hand rear passenger power
window control switch C711 pin 2, circuit 31S-
AJ63A (BK/BU) harness side.
NOTE: Right-hand Rear Passenger Power
Window
- the driver power window control switch C709
pin 10, circuit 31S-AJ60 (BK/BU) harness
side and the right-hand rear passenger power
window control switch C712 pin 2, circuit 31S-
AJ63A (BK/BU) harness side.
• Is the resistance less than 5 ohms?
→ Yes
GO to C3
→ No
REPAIR circuit 31S-AJ63A (BK/BU). TEST
the system for normal operation.
C3: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH AND THE MOTOR UP CIRCUIT
1 Measure the resistance between
NOTE: Left-hand Rear Passenger Power Window
- the driver power window control switch C709
pin 3, circuit 31S-AJ58 (BK/OG) harness side
and the left-hand rear passenger power
window control switch C711 pin 5, circuit 31S-
AJ64A (BK/OG) harness side.
NOTE: Right-hand Rear Passenger Power
Window
- the driver power window control switch C709
pin 11, circuit 31S-AJ61 (BK/OG) harness
side and the right-hand rear passenger power
window control switch C712 pin 5, circuit 31S-
AJ64A (BK/OG) harness side.
• Is the resistance less than 5 ohms?
→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 31S-AJ64A (BK/OG). TEST
the system for normal operation.
C4: CHECK FOR VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW CONTROL
SWITCH
1 Key in ON position.
• Does the inoperative passenger power window
control switch LED illuminate?
→ Yes
GO to C5
→ No

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501-11-15 Glass, Frames and Mechanisms 501-11-15

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to C10
C5: CHECK FOR BATTERY VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR
1 Key in OFF position.
2 Disconnect Inoperative Passenger Power Win-
dow Motor C707 or C708.
3 Key in ON position.
4 Measure the voltage between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
control switch C707 pin 7, circuit 29-AJ31
(OG/BU) harness side and ground.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window con-
trol switch C708 pin 7, circuit 29-AJ31
(OG/BU) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to C6
→ No
REPAIR circuit 29-AJ31 (OG/BU). TEST the
system for normal operation.
C6: CHECK FOR IGNITION VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR
1 Measure the voltage between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
motor C707 pin 2, circuit 15-AJ31 (GN/BU)
harness side and ground.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window mo-
tor C708 pin 2, circuit 15-AJ31 (GN/BU) har-
ness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to C7
→ No
REPAIR circuit 15-AJ31 (GN/BU). TEST the
system for normal operation.

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501-11-16 Glass, Frames and Mechanisms 501-11-16

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C7: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR AND GROUND
1 Key in OFF position.
2 Measure the resistance between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
motor C707 pin 8, circuit 31-AJ31 (BK)
harness side and ground.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window mo-
tor C708 pin 8, circuit 31-AJ31 (BK) harness
side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to C8
→ No
REPAIR circuit 31-AJ31 (BK). TEST the
system for normal operation.
C8: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR DOWN CIRCUIT AND GROUND
1 Disconnect Inoperative Passenger Power Win-
dow Control Switch C711 or C712.
2 Operate and hold the inoperative passenger
power window motor control switch in the
DOWN position.
3 Measure the resistance between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
motor C707 pin 4, circuit 31S-AJ63 (BK/BU)
harness side and the inoperative passenger
power window control switch C711 pin 2,
circuit 31S-AJ63A (BK/BU) harness side.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window mo-
tor C708 pin 4, circuit 31S-AJ63 (BK/BU) har-
ness side and the inoperative passenger
power window control switch C712 pin 2, cir-
cuit 31S-AJ63A (BK/BU) harness side.
• Is the resistance less than 5 ohms?
→ Yes
GO to C9
→ No
REPAIR circuit 31S-AJ63 (BK/BU). TEST
the system for normal operation.

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501-11-17 Glass, Frames and Mechanisms 501-11-17

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
C9: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR UP CIRCUIT AND GROUND
1 Operate and hold the inoperative passenger
power window motor control switch in the UP
position.
2 Measure the resistance between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
motor C707 pin 3, circuit 31S-AJ64 (BK/OG)
harness side and the inoperative passenger
power window control switch C711 pin 5,
circuit 31S-AJ64A (BK/OG) harness side.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window mo-
tor C708 pin 3, circuit 31S-AJ64 (BK/OG)
harness side and the inoperative passenger
power window control switch C712 pin 5, cir-
cuit 31S-AJ64A (BK/OG) harness side.
• Is the resistance less than 5 ohms?
→ Yes
INSTALL a new motor. REFER to the pro-
cedure in this Section: Door Window Regu-
lator and Motor. TEST the system for nor-
mal operation.
→ No
REPAIR circuit 31S-AJ64 (BK/OG). TEST
the system for normal operation.
C10: CHECK THE INOPERATIVE PASSENGER POWER WINDOW CONTROL SWITCH GROUND
CIRCUIT
1 Key in OFF position.
2 Disconnect Inoperative Passenger Power Win-
dow Control Switch C711 or C712.
3 Measure the resistance between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
control switch C711 pin 6, circuit 31S-AJ32
(BK/OG) harness side and the driver power
window control switch C709 pin 1, circuit 31S-
AJ1 (BK/BU) harness side.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window con-
trol switch C711 pin 6, circuit 31S-AJ32
(BK/OG) harness side and the driver power
window control switch C709 pin 1, circuit 31S-
AJ1 (BK/BU) harness side.
• Is the resistance less than 5 ohms?
→ Yes
GO to C11
→ No
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501-11-18 Glass, Frames and Mechanisms 501-11-18

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 31S-AJ32 (BK/OG). TEST
the system for normal operation.
C11: CHECK FOR IGNITION VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH
1 Key in ON position.
2 Measure the voltage between:
NOTE: Left-hand Rear Passenger Power Window
- the inoperative passenger power window
control switch C711 pin 1, circuit 15-LH36
(GN/RD) harness side and ground.
NOTE: Right-hand Rear Passenger Power
Window
- the inoperative passenger power window con-
trol switch C712 pin 1, circuit 15-LH36
(GN/RD) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 15-LH36 (GN/RD). TEST the
system for normal operation.
PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE - DRIVER SIDE
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
1 Key in ON position.
• Does the driver power window control switch
LED illuminate?
→ Yes
GO to D2
→ No
GO to D7
D2: CHECK FOR BATTERY VOLTAGE TO THE DRIVER POWER WINDOW MOTOR
1 Key in OFF position.
2 Disconnect Driver power window motor C705.
3 Key in ON position.

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501-11-19 Glass, Frames and Mechanisms 501-11-19

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the driver power
window motor C705 pin 7, circuit 29-AJ26
(OG/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to D3
→ No
REPAIR circuit 29-AJ26 (OG/YE). TEST the
system for normal operation.
D3: CHECK FOR IGNITION VOLTAGE TO THE DRIVER POWER WINDOW MOTOR
1 Measure the voltage between the driver power
window motor C705 pin 2, circuit 15-AJ26A
(GN/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to D4
→ No
REPAIR circuit 15-AJ26A (GN/YE). TEST
the system for normal operation.
D4: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW MOTOR AND
GROUND
1 Key in OFF position.

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501-11-20 Glass, Frames and Mechanisms 501-11-20

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the driver
power window motor C705 pin 8, circuit 31-
AJ26 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to D5
→ No
REPAIR circuit 31-AJ26 (BK). TEST the
system for normal operation.
D5: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW MOTOR UP CIRCUIT
AND GROUND
1 Operate and hold the inoperative driver power
window motor control switch in the UP position.
2 Measure the resistance between the driver
power window motor C705 pin 4, circuit 31S-
AJ40 (BK/GN) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to D6
→ No
REPAIR circuit 31S-AJ40 (BK/GN). TEST
the system for normal operation.
D6: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW MOTOR DOWN
CIRCUIT AND GROUND
1 Operate and hold the inoperative driver power
window motor control switch in the DOWN po-
sition.

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501-11-21 Glass, Frames and Mechanisms 501-11-21

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the driver
power window motor C705 pin 3, circuit 31S-
AJ41 (BK/RD) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new motor. REFER to the pro-
cedure in this Section: Door Window Regu-
lator and Motor. TEST the system for nor-
mal operation.
→ No
REPAIR circuit 31S-AJ41 (BK/RD). TEST
the system for normal operation.
D7: CHECK THE DRIVER POWER WINDOW CONTROL SWITCH GROUND CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Power Window Control
Switch C709.
3 Measure the resistance between the driver
power window control switch C709 pin 4, circuit
31-AJ7 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to D8
→ No
REPAIR circuit 31-AJ7 (BK). TEST the sys-
tem for normal operation.
D8: CHECK FOR IGNITION VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
1 Key in ON position.

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501-11-22 Glass, Frames and Mechanisms 501-11-22

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the driver power
window control switch C709 pin 13, circuit 15-
LH14 (GN/YE) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 15-LH14 (GN/YE). TEST the
system for normal operation.
PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE - PASSENGER SIDE
CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE INOPERATIVE WINDOW FOR OPERATION FROM THE DRIVER POWER
WINDOW CONTROL SWITCH
1 Key in ON position.
2 Operate the passenger power window from the
driver power window control switch.
• Does the passenger power window operate
correctly?
→ Yes
GO to E2
→ No
GO to E4
E2: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH AND THE MOTOR DOWN CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Power Window Control
Switch C709.
3 Disconnect Passenger Power Window Control
Switch C710.

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501-11-23 Glass, Frames and Mechanisms 501-11-23

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
NOTE: Left-hand Drive
- the inoperative passenger power window
motor C710 pin 2, circuit 31S-AJ54B (BK/GN)
harness side and the driver power window
control switch C709 pin 14, circuit 31S-AJ54
(BK/GN) harness side.
NOTE: Right-hand Drive
- the inoperative passenger power window mo-
tor C710 pin 2, circuit 31S-AJ54B (BK/GN)
harness side and the driver power window
control switch C709 pin 6, circuit 31S-AJ54
(BK/GN) harness side.

• Is the resistance less than 5 ohms?

→ Yes
GO to E3
→ No
REPAIR circuit 31S-AJ54B (BK/RD). TEST
the system for normal operation.
E3: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL
SWITCH AND THE MOTOR UP CIRCUIT
1 Measure the resistance between:
NOTE: Left-hand Drive
- the inoperative passenger power window
motor C710 pin 5, circuit 31S-AJ55B (BK/RD)
harness side and the driver power window
control switch C709 pin 15, circuit 31S-AJ55
(BK/RD) harness side.
NOTE: Right-hand Drive
- the inoperative passenger power window mo-
tor C710 pin 5, circuit 31S-AJ55B (BK/RD)
harness side and the driver power window
control switch C709 pin 7, circuit 31S-AJ55
(BK/RD) harness side.

• Is the resistance less than 5 ohms?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 31S-AJ55B (BK/RD). TEST
the system for normal operation.
E4: CHECK FOR VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW CONTROL
SWITCH
1 Key in ON position.
• Does the passenger power window control
switch LED illuminate?
→ Yes
GO to E5
→ No
GO to E10

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501-11-24 Glass, Frames and Mechanisms 501-11-24

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
E5: CHECK FOR BATTERY VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR
1 Key in OFF position.
2 Disconnect Passenger Power Window Motor
C706.
3 Key in ON position.
4 Measure the voltage between the passenger
power window motor C706 pin 7, circuit 29-
AJ27 (OG/WH) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to E6
→ No
REPAIR circuit 29-AJ27 (OG/WH). TEST
the system for normal operation.
E6: CHECK FOR IGNITION VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR
1 Measure the voltage between the passenger
power window motor C706 pin 2, circuit 15-
AJ27A (GN/WH) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to E7
→ No
REPAIR circuit 15-AJ27A (GN/WH). TEST
the system for normal operation.
E7: CHECK THE INOPERATIVE PASSENGER POWER WINDOW MOTOR GROUND CIRCUIT
1 Key in OFF position.

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501-11-25 Glass, Frames and Mechanisms 501-11-25

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the passen-
ger power window motor C706 pin 8, circuit 31-
AJ27 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to E8
→ No
REPAIR circuit 31-AJ27 (BK). TEST the
system for normal operation.
E8: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR DOWN CIRCUIT AND GROUND
1 Operate and hold the inoperative passenger
power window motor control switch in the
DOWN position.
2 Measure the resistance between the passen-
ger power window motor C706 pin 4, circuit
31S-AJ54A (BK/GN) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to E9
→ No
REPAIR circuit 31S-AJ54A (BK/GN). TEST
the system for normal operation.
E9: CHECK FOR CONTINUITY BETWEEN THE INOPERATIVE PASSENGER POWER WINDOW
MOTOR UP CIRCUIT AND GROUND
1 Operate and hold the inoperative passenger
power window motor control switch in the UP
position.

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501-11-26 Glass, Frames and Mechanisms 501-11-26

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between the passen-
ger power window motor C706 pin 3, circuit
31S-AJ55A (BK/RD) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new motor. REFER to the pro-
cedure in this Section: Door Window Regu-
lator and Motor. TEST the system for nor-
mal operation.
→ No
REPAIR circuit 31S-AJ55A (BK/RD). TEST
the system for normal operation.
E10: CHECK THE INOPERATIVE PASSENGER POWER WINDOW CONTROL SWITCH GROUND
CIRCUIT
1 Key in OFF position.
2 Disconnect Passenger Power Window Control
Switch C710.
3 Measure the resistance between the passen-
ger power window control switch C710 pin 6,
circuit 31-AJ18 (BK) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to E11
→ No
REPAIR circuit 31-AJ18 (BK). TEST the
system for normal operation.
E11: CHECK FOR IGNITION VOLTAGE TO THE INOPERATIVE PASSENGER POWER WINDOW
CONTROL SWITCH
1 Key in ON position.

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501-11-27 Glass, Frames and Mechanisms 501-11-27

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between the passenger
power window control switch C710 pin 1, circuit
15-LH31 (GN/BU) harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 15-LH31 (GN/BU). TEST the
system for normal operation.

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501-11-28 Glass, Frames and Mechanisms 501-11-28

GENERAL PROCEDURES

Door Window Motor Initialization

GENERAL PROCEDURES

WARNING: The door window anti-trap

function will not operate during the door
window motor initialization procedure.
Make sure that the door window opening
is free of all foreign material. Failure to
follow this instruction may result in
personal injury.
NOTE: After the battery has been disconnected it
is necessary to initialize each door window motor
separately.
1. Press the power window control switch
close button until the door window is fully
closed and hold the button in the close
position for a further second.
2. Release the power window control switch
close button and press again two or three
more times, for one second each time.
3. Press the power window control switch
open button until the door window is fully
open.
4. Briefly press the power window control
switch close button to the second detent
and release the button.
• If the door window does not close
automatically, repeat the complete
procedure.
5. Repeat the door window motor
initialization for each door window motor.

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501-11-29 Glass, Frames and Mechanisms 501-11-29

REMOVAL AND INSTALLATION

Front Door Window Glass (42 314 0)

REMOVAL AND INSTALLATION

Removal 4. Remove the speaker.

1. Lower the front door window glass to the • Disconnect the electrical connector.
position shown.

5. CAUTION: Do not touch the adhesive

2. Remove the front door trim panel. For surface as re-bonding will be
additional information, refer to Section impaired.
501-05.
Detach the watershield from the front door
3. Detach the speaker from the front door panel.
panel.

6. Loosen the front door window glass clamp

bolts.

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501-11-30 Glass, Frames and Mechanisms 501-11-30

REMOVAL AND INSTALLATION (Continued)

7. Remove the front door window glass

weatherstrip.

8. NOTE: The front door window glass must be

removed towards the outside of the window
opening.
Remove the front door window glass.
1. Lift the glass.
2. Tip the glass forwards and remove the
glass from the front door.

Installation
1. NOTE: The front door window glass must be
installed towards the outside of the window
opening.
To install, reverse the removal procedure.

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501-11-31 Glass, Frames and Mechanisms 501-11-31

REMOVAL AND INSTALLATION

Rear Door Window Glass (42 315 0)

Removal 4. Remove the rear door handle support

bracket.
1. Lower the rear door window glass to the
position shown.

5. CAUTION: Do not touch the adhesive

2. Remove the rear door trim panel. For surface as re-bonding will be
additional information, refer to Section impaired.
501-05. Detach the watershield from the rear door
3. Remove the rear door window glass open- panel.
ing inner weatherstrip.

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501-11-32 Glass, Frames and Mechanisms 501-11-32

REMOVAL AND INSTALLATION (Continued)

6. Detach the rear door window glass from 2. CAUTION: Do not touch the adhesive
the window regulator and remove the rear surface as re-bonding will be
door window glass. impaired.
• Access the window glass retaining clip
Attach the watershield to the rear door
from both sides, detach the window glass
panel.
retaining clip and lift the window glass.

3. Install the rear door handle support

bracket.
Installation
1. Install the rear door window glass.
• Push the rear door window glass down
firmly onto the rear door window regulator
to engage the window glass retaining clip.

4. Install the rear door window glass opening

inner weatherstrip.

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501-11-33 Glass, Frames and Mechanisms 501-11-33

REMOVAL AND INSTALLATION (Continued)

5. Install the rear door trim panel. For

additional information, refer to Section
501-05.

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501-11-34 Glass, Frames and Mechanisms 501-11-34

REMOVAL AND INSTALLATION

Rear Quarter Window Glass — 4-Door/5-Door (42 514 0)

Removal
4. CAUTION: Do not touch the adhesive
1. Lower the rear door window glass to the surface as re-bonding will be
position shown. impaired.
Detach the watershield from the rear door
panel.

2. Remove the rear door trim panel. For

additional information, refer to Section
501-05. 5. Detach the rear door window glass from
3. Remove the rear door handle support the window regulator and lower the
bracket. window glass to the base of the door.
• Access the window glass retaining clip
from both sides, detach the window glass
retaining clip and lift the window glass.

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501-11-35 Glass, Frames and Mechanisms 501-11-35

REMOVAL AND INSTALLATION (Continued)

6. Detach the rear door glass top run from 9. Remove the rear quarter window glass re-
the rear door window opening. taining screws.

7. Remove the rear quarter window glass trim 10. Remove the rear quarter window glass.
panel. • Tip the glass forwards and remove the
glass from the rear door.

8. Remove the rear quarter window glass

screw cover.
Installation
1. Install the rear quarter window glass.

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501-11-36 Glass, Frames and Mechanisms 501-11-36

REMOVAL AND INSTALLATION (Continued)

2. Install the rear quarter window glass re- 5. Attach the rear door glass top run to the
taining screws. rear door window opening.

3. Install the rear quarter window glass screw 6. Install the rear door window glass.
cover. • Push the rear door window glass down
firmly onto the rear door window regulator
to engage the window glass retaining clip.

4. Install the rear quarter window glass trim

panel.
7. CAUTION: Do not touch the adhesive
surface as re-bonding will be
impaired.
Attach the watershield to the rear door
panel.

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501-11-37 Glass, Frames and Mechanisms 501-11-37

REMOVAL AND INSTALLATION (Continued)

8. Install the rear door handle support

bracket.

9. Install the rear door trim panel. For

additional information, refer to Section
501-05.

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501-11-38 Glass, Frames and Mechanisms 501-11-38

REMOVAL AND INSTALLATION

Rear Quarter Window Glass — Wagon (42 514 0)

3. WARNING: Wear gloves and eye

General Equipment
protection when working with the
Hot air gun glass cutting tool as the cutting
operation may produce splinters.
Direct glazing cutter for bonded glass When using the cutter wear ear
Direct glazing adhesive kit protectors. Failure to follow these
instructions may result in personal
Direct glazing adhesive oven injury.
Glazing suction cups
CAUTION: Make sure the cutting blades
are changed where the cutting depth
changes to avoid damage to the body
Removal and trim panels.
1. Remove the polyurethane (PU) adhesive CAUTION: On vehicles equipped with a
cap and heat the PU adhesive for a mini- diversity antenna, make sure the cutting
mum of 30 minutes blades do not damage the antenna grid
wire.
NOTE: Some resistance may be encountered
when cutting through the glass locating pegs in
the lower corners of the glass.
Using a suitable direct glazing cutter, cut
the PU adhesive and, with the aid of
another technician, use glazing suction
cups to remove the rear quarter window
glass.
• Cut the PU adhesive from inside the
vehicle to the given maximum depths.
1. 10 mm
2. 15 mm
2. Disconnect the diversity antenna electrical
connector (if equipped).

Installation
1. Carefully remove the remaining part of the
locating pegs from the rear quarter
window glass flange.

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501-11-39 Glass, Frames and Mechanisms 501-11-39

REMOVAL AND INSTALLATION (Continued)

2. Carefully trim the remaining PU adhesive the rear quarter window glass flange along
from the rear quarter window glass flange the bond line.
to leave approximately 1 mm of trimmed
PU adhesive adhered to the flange.

7. With the aid of another technician, use

glazing suction cups to install the rear
3. Check the rear quarter window glass quarter window glass.
flange for damaged sheet metal, rust or • Press firmly and evenly into position.
foreign material which may have caused,
or may cause, glass breakage.
4. CAUTION: During the curing period of
the PU adhesive, the door windows
must be left open to avoid a build up
of pressure when the doors are
opened and closed.
CAUTION: Do not touch the adhesive
surface as re-bonding will be impaired.
CAUTION: To make sure that the PU
adhesive cures, it is essential that all
bonding surfaces are free of moisture.
Using a hot air gun, apply warm air (25°C) 8. Using suitable tape, secure the rear
to the rear quarter window glass flange quarter window glass in the correct
and glass bond line to remove all traces of position until the PU adhesive has cured.
moisture.
9. If the ambient temperature falls below
5. Prepare the glass, rear quarter window 10°C, use a hot air gun and apply warm air
glass flange and trimmed PU adhesive in (25°C) continuously for 15 minutes (inside
accordance with the instructions supplied or outside the vehicle).
with the adhesive kit.
6. CAUTION: On vehicles equipped with
diversity antenna, make sure the PU
adhesive does not cover the antenna
grid wire.
NOTE: Discard the first 100 mm of PU adhesive
as this may have a reduced working time.
NOTE: To avoid water leaks, any breakage in the
continuous bead must be overlapped by 20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm in height to

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501-11-40 Glass, Frames and Mechanisms 501-11-40

REMOVAL AND INSTALLATION (Continued)

10. Connect the diversity antenna electrical

connector (if equipped).

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501-11-41 Glass, Frames and Mechanisms 501-11-41

REMOVAL AND INSTALLATION

Rear Window Glass — 4-Door

3. Disconnect the electrical connector and
remove the high mounted stoplamp.
General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups

Removal
1. Remove the polyurethane (PU) adhesive
cap and heat the PU adhesive for a mini- 4. Remove the rear seat backrest outer head
mum of 30 minutes. restraints.
5. Detach the C-pillar trim panels from the C-
pillars and position them to one side (left-
hand side shown).

2. Remove the high mounted stoplamp cover.

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501-11-42 Glass, Frames and Mechanisms 501-11-42

REMOVAL AND INSTALLATION (Continued)

6. Detach the rear of the headliner from the 9. WARNING: Wear gloves and eye
roof panel. protection when working with the
• Place blocks of suitable material between glass cutting tool as the cutting
the headliner and the roof panel to act as operation may product splinters.
spacers. When using the cutter wear ear
protectors. Failure to follow these
instructions may result in personal
injury.
CAUTION: Make sure the cutting blades
are changed where the cutting depth
changes to avoid damage to the body
and trim panels.
CAUTION: On vehicles equipped with a
diversity antenna, make sure the cutting
blades do not damage the antenna grid
wire.
Using a suitable direct glazing cutter, cut
the PU adhesive and, with the aid of
7. Disconnect the heated rear window glass another technician, use glazing suction
electrical connectors (right-hand side cups to remove the rear window glass.
shown). • Cut the PU adhesive from inside the
vehicle to the given maximum depths.
1. 20 mm.
2. 23 mm.
3. 35 mm.
4. 40 mm.
5. 45 mm.

8. Disconnect the diversity antenna electrical

connector (if equipped).

Installation
1. Carefully trim the remaining PU adhesive
from the rear window glass flange to leave

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501-11-43 Glass, Frames and Mechanisms 501-11-43

REMOVAL AND INSTALLATION (Continued)

approximately 1 mm of trimmed PU adhe-

sive adhered to the flange.
5. CAUTION: On vehicles equipped with a
diversity antenna, make sure the PU
adhesive does not cover the antenna
grid wire.
NOTE: Discard the first 100 mm of PU adhesive
as this may have a reduced working time.
NOTE: To avoid water leaks, any breakage in the
continuous bead must be overlapped by 20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm in height to
the rear window glass flange along the
bond line.

2. Check the rear window glass flange for

damaged sheet metal, rust or foreign
material which may have caused, or may
cause, glass breakage.
3. CAUTION: Do not touch the adhesive
surface as re-bonding will be
impaired.
CAUTION: To make sure that the PU
adhesive cures, it is essential that all
bonding surfaces are free of moisture.
Using a hot air gun, apply warm air (25°C)
to the rear window glass flange and glass 6. With the aid of another technician, use
bond line to remove all traces of moisture. glazing suction cups to install the rear
window glass.
4. Prepare the glass, rear window glass
flange and trimmed PU adhesive in • Press firmly and evenly into position.
accordance with the instructions supplied
with the PU adhesive kit.

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501-11-44 Glass, Frames and Mechanisms 501-11-44

REMOVAL AND INSTALLATION (Continued)

11. Attach the rear of the headliner to the

7. CAUTION: During the curing period of
roof panel.
the PU adhesive, the door windows
must be left open to avoid a build up • Remove the spacers.
of pressure when the doors are
opened and closed.
Using suitable tape, secure the rear
window glass in the correct position until
the PU adhesive has cured.
8. If the ambient temperature falls below
10°C, use a hot air gun and apply warm air
(25°C) continuously for 15 minutes (inside
or outside the vehicle).

12. Attach the C-pillar trim panels to the C-

pillars (left-hand side shown).

9. Connect the heated rear window glass

electrical connectors (right-hand side
shown).

13. Install the rear seat backrest outer head

restraints.
14. Connect the high mounted stoplamp
electrical connector.

10. Connect the diversity antenna electrical

connector (if equipped).

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501-11-45 Glass, Frames and Mechanisms 501-11-45

REMOVAL AND INSTALLATION (Continued)

15. Install the high mounted stoplamp.

16. Install the high mounted stoplamp cover.

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501-11-46 Glass, Frames and Mechanisms 501-11-46

REMOVAL AND INSTALLATION

Rear Window Glass — 5-Door

3. Remove the rear window wiper arm (if
equipped).
General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups

Removal
1. Remove the polyurethane (PU) adhesive
cap and heat the PU adhesive for a mini- 4. Remove the liftgate trim panel.
mum of 30 minutes.

5. Detach the high mounted stoplamp from

2. Remove the parcel shelf. the liftgate.

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501-11-47 Glass, Frames and Mechanisms 501-11-47

REMOVAL AND INSTALLATION (Continued)

6. Disconnect the electrical connector and 10. WARNING: Wear gloves and eye
remove the high mounted stoplamp. protection when working with the
glass cutting tool as the cutting
operation may product splinters.
When using the cutter wear ear
protectors. Failure to follow these
instructions may result in personal
injury.
CAUTION: Make sure the cutting blades
are changed where the cutting depth
changes to avoid damage to the body
and trim panels.
CAUTION: On vehicles equipped with a
diversity antenna, make sure the cutting
blades do not damage the antenna grid
7. Remove the liftgate side trim panels. wire.
NOTE: Some resistance may be encountered
when cutting through the glass locating pegs in
the lower corners of the glass.
Using a suitable direct glazing cutter, cut
the PU adhesive and, with the aid of
another technician, use glazing suction
cups to remove the rear window glass.
• Cut the PU adhesive from inside the
vehicle to the given maximum depths.
1. 35 mm.
2. 30 mm.
3. 125 mm.
4. 150 mm.
8. Disconnect the heated rear window glass 5. 135 mm.
electrical connectors (right-hand side
shown).

Installation
9. Disconnect the diversity antenna electrical
connector (if equipped). 1. Carefully remove the remaining part of the
locating pegs from the rear window glass
flange.
G70851 en 08/2002 2003.0 Mondeo
501-11-48 Glass, Frames and Mechanisms 501-11-48

REMOVAL AND INSTALLATION (Continued)

2. Carefully trim the remaining PU adhesive 6. CAUTION: On vehicles equipped with a

from the rear window glass flange to leave diversity antenna, make sure the PU
approximately 1 mm of trimmed PU adhe- adhesive does not cover the antenna
sive adhered to the flange. grid wire.
NOTE: Discard the first 100 mm of PU adhesive
as this may have a reduced working time.
NOTE: To avoid water leaks, any breakage in the
continuous bead must be overlapped by 20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm in height to
the rear window glass flange along the
bond line.

3. Check the rear window glass flange for

damaged sheet metal, rust or foreign
material which may have caused, or may
cause, glass breakage.
4. CAUTION: Do not touch the adhesive
surface as re-bonding will be
impaired.
CAUTION: To make sure that the PU
adhesive cures, it is essential that all 7. With the aid of another technician, use
bonding surfaces are free of moisture. glazing suction cups to install the rear
window glass.
Using a hot air gun, apply warm air (25°C)
• Press firmly and evenly into position.
to the rear window glass flange and glass
bond line to remove all traces of moisture.
5. Prepare the glass, rear window glass
flange and trimmed PU adhesive in
accordance with the instructions supplied
with the PU adhesive kit.

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501-11-49 Glass, Frames and Mechanisms 501-11-49

REMOVAL AND INSTALLATION (Continued)

8. CAUTION: During the curing period of 12. Install the liftgate side trim panels.
the PU adhesive, the door windows
must be left open to avoid a build up
of pressure when the doors are
opened and closed.
Using suitable tape, secure the rear
window glass in the correct position until
the PU adhesive has cured.
9. If the ambient temperature falls below
10°C, use a hot air gun and apply warm air
(25°C) continuously for 15 minutes (inside
or outside the vehicle).

13. Connect the high mounted stoplamp

electrical connector.

10. Connect the heated rear window glass

electrical connectors (right-hand side
shown).

14. Attach the high mounted stoplamp to the

liftgate.

11. Connect the diversity antenna electrical

connector (if equipped).

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501-11-50 Glass, Frames and Mechanisms 501-11-50

REMOVAL AND INSTALLATION (Continued)

15. Install the liftgate trim panel.

16. Install the rear window wiper arm (if

equipped).

17. Install the parcel shelf.

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501-11-51 Glass, Frames and Mechanisms 501-11-51

REMOVAL AND INSTALLATION

Rear Window Glass — Wagon

4. Detach the high mounted stoplamp from

General Equipment the liftgate.

Hot air gun

Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups

Removal
1. Remove the polyurethane (PU) adhesive
cap and heat the PU adhesive for a mini-
mum of 30 minutes.
5. Disconnect the electrical connector and
remove the high mounted stoplamp.

2. Remove the rear window wiper motor. For

additional information, refer to Section
501-16. 6. Remove the liftgate side trim panels.
3. Remove the rear window wiper motor
spindle grommet.
1. Remove the sleeve.
2. Remove the grommet.

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501-11-52 Glass, Frames and Mechanisms 501-11-52

REMOVAL AND INSTALLATION (Continued)

7. Disconnect the heated rear window glass Installation
electrical connectors (right-hand side
shown). 1. Carefully remove the remaining part of the
locating pegs from the window glass
flange.
2. Carefully trim the remaining PU adhesive
from the rear window glass flange to leave
approximately 1 mm of trimmed PU adhe-
sive adhered to the flange.

8. WARNING: Wear gloves and eye

protection when working with the
glass cutting tool as the cutting
operation may product splinters.
When using the cutter wear ear
protectors. Failure to follow these
instructions may result in personal 3. Check the window glass flange for
injury. damaged sheet metal, rust or foreign
material which may have caused, or may
CAUTION: Make sure the cutting blades cause, glass breakage.
are changed where the cutting depth
changes to avoid damage to the body 4. CAUTION: Do not touch the adhesive
and trim panels. surface as re-bonding will be
NOTE: Some resistance may be encountered impaired.
when cutting through the glass locating pegs in CAUTION: To make sure that the PU
the lower corners of the glass. adhesive cures, it is essential that all
Using a suitable direct glazing cutter, cut bonding surfaces are free of moisture.
the PU adhesive and, with the aid of Using a hot air gun, apply warm air (25°C)
another technician, use glazing suction to the rear window glass flange and glass
cups to remove the rear window glass. bond line to remove all traces of moisture.
• Cut the PU adhesive from inside the vehi- 5. Prepare the glass, rear window glass
cle to a maximum depth of 25 mm. flange and trimmed PU adhesive in
accordance with the instructions supplied
with the PU adhesive kit.

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501-11-53 Glass, Frames and Mechanisms 501-11-53

REMOVAL AND INSTALLATION (Continued)

6. NOTE: Discard the first 100 mm of PU 9. If the ambient temperature falls below
adhesive as this may have a reduced working 10°C, use a hot air gun and apply warm air
time. (25°C) continuously for 15 minutes (inside
NOTE: To avoid water leaks, any breakage in the or outside the vehicle).
continuous bead must be overlapped by 20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm in height to
the rear window glass flange along the
bond line.

10. Connect the heated rear window glass

electrical connectors (right-hand side
shown).

7. With the aid of another technician, use

glazing suction cups to install the rear
window glass.
• Press firmly and evenly into position.

11. Install the liftgate side trim panels.

8. CAUTION: During the curing period of

the PU adhesive, the door windows
must be left open to avoid a build up
of pressure when the doors are
opened and closed.
Using suitable tape, secure the rear
window glass in the correct position until
the PU adhesive has cured.

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501-11-54 Glass, Frames and Mechanisms 501-11-54

REMOVAL AND INSTALLATION (Continued)

12. Connect the high mounted stoplamp
electrical connector.

13. Attach the high mounted stoplamp to the

liftgate.

14. Install the rear window wiper motor

spindle grommet.
1. Install the grommet.
2. Install the sleeve.

15. Install the rear window wiper motor. For

additional information, refer to Section
501-16.

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501-11-55 Glass, Frames and Mechanisms 501-11-55

REMOVAL AND INSTALLATION

Windshield Glass (42 115 0)

4. Remove the cowl panels.
• Pull the cowl panels out of the retaining
General Equipment groove.

Hot air gun

Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups

Removal
All vehicles
1. Remove the polyurethane (PU) adhesive
cap and heat the PU adhesive for a mini-
mum of 30 minutes. Vehicles with heated windshield
5. Disconnect the heated windshield electri-
cal connectors (left-hand side shown).

2. Raise the hood.

3. NOTE: Make sure that the windshield wiper All vehicles
motor is in the park position. 6. Lower the hood.
Remove the windshield wiper arms. 7. Remove the A-pillar exterior trim panels.

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501-11-56 Glass, Frames and Mechanisms 501-11-56

REMOVAL AND INSTALLATION (Continued)

Vehicles with manual dimming interior mirror
12. Remove the overhead console. For
8. Remove the manual dimming interior
additional information, refer to Section
mirror.
501-12.
• Release the clip.
13. Remove the A-pillar trim panels. For
additional information, refer to Section
501-05.
14. Detach the leading edge of the headliner
and place two blocks of suitable material
between the headliner and the roof panel
to act as spacers.

Vehicles with auto-dimming interior mirror

9. Remove the auto-dimming interior mirror.
For additional information, refer to Section
501-09.
All vehicles
10. Remove the sun visors.

11. Lever open the covers to expose the

screws and remove the sun visor retain-
ing clips.

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501-11-57 Glass, Frames and Mechanisms 501-11-57

REMOVAL AND INSTALLATION (Continued)

15. WARNING: Wear gloves and eye 2. CAUTION: Do not touch the adhesive
protection when working with the surface as re-bonding will be
glass cutting tool as the cutting impaired.
operation may produce splinters.
Carefully trim the remaining PU adhesive
When using the cutter wear ear
from the windshield glass flange to leave
protectors. Failure to follow these
approximately 1 mm of trimmed PU adhe-
instructions may result in personal
sive adhered to the flange.
injury.
CAUTION: Make sure the cutting blades
are changed where the cutting depth
changes to avoid damage to the body
and trim panels.
NOTE: Some resistance may be encountered
when cutting through the glass locating pegs in
the lower corners of the glass.
NOTE: Care must be taken when cutting in the
area of the locating blocks along the lower edge
of the windshield glass.
Using a suitable direct glazing cutter, cut
the PU adhesive and, with the aid of
another technician, use glazing suction
cups to remove the windshield glass. 3. Check the windshield glass flange for
damaged sheet metal, rust or foreign
• Cut the PU adhesive from inside the material which may have caused, or may
vehicle to the given maximum depths. cause, glass breakage.
1. 15 mm.
2. 20 mm. 4. CAUTION: To make sure that the PU
adhesive cures, it is essential that all
3. 25 mm. bonding surfaces are free of moisture.
4. 40 mm.
Using a hot air gun, apply warm air (25°C)
5. 70 mm. to the windshield glass flange and glass
bond line to remove all traces of moisture.
5. Prepare the glass, windshield glass flange
and trimmed PU adhesive in accordance
with the instructions supplied with the PU
adhesive kit.

Installation
All vehicles
1. Carefully remove the remaining part of the
glass locating pegs from the windshield
glass flange.

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501-11-58 Glass, Frames and Mechanisms 501-11-58

REMOVAL AND INSTALLATION (Continued)

6. NOTE: Discard the first 100 mm of PU 9. If the ambient temperature falls below
adhesive as this may have a reduced working 10°C, use a hot air gun and apply warm air
time. (25°C) continuously for 15 minutes (inside
NOTE: To avoid water leaks, any breakage in the or outside the vehicle).
continuous bead must be overlapped by 20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm in height to
the windshield glass flange along the bond
line.

10. Remove the spacers and attach the lead-

ing edge of the headliner to the roof
panel.

7. With the aid of another technician, use

glazing suction cups to install the
windshield glass.
• Press firmly and evenly into position.

11. Install the A-pillar trim panels. For

additional information, refer to Section
501-05.
12. Install the overhead console. For
additional information, refer to Section
501-12.

8. CAUTION: During the curing period of

the PU adhesive, the door windows
must be left open to avoid a build up
of pressure when the doors are open
and closed.
Using suitable tape, secure the windshield
glass in the correct position until the PU
adhesive has cured.

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501-11-59 Glass, Frames and Mechanisms 501-11-59

REMOVAL AND INSTALLATION (Continued)

13. Install the sun visor retaining clips. 18. Raise the hood.
Vehicles with heated windshield
19. Connect the heated windshield electrical
connectors.

14. Install the sun visors.

All vehicles
20. Install the cowl panels.

Vehicles with manual dimming interior mirror

15. Install the manual dimming interior
mirror.
Vehicles with auto-dimming interior mirror
16. Instal the auto-dimming interior mirror. 21. Install the windshield wiper arms.
For additional information, refer to
Section 501-09.
All vehicles
17. Install the A-pillar exterior trim panels.

22. Lower the hood.

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501-11-60 Glass, Frames and Mechanisms 501-11-60

REMOVAL AND INSTALLATION

Front Door Window Regulator and Motor (42 338 0)

Removal 5. Remove the speaker housing.

All vehicles
1. Remove the front door window glass. For
additional information, refer to Front Door
Window Glass in this section.
2. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
3. Remove the front door handle support
bracket.

Vehicles with power mirrors

6. Detach the power mirror electrical connec-
tor from the door panel.

4. Detach the power window wiring harness

retaining clips from the door panel.

All vehicles
7. CAUTION: Do not touch the adhesive
surface as re-bonding will be
impaired.
Remove the watershield.

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501-11-61 Glass, Frames and Mechanisms 501-11-61

REMOVAL AND INSTALLATION (Continued)

8. Disconnect the front door window regula- 2. Initialize the door window motors. For
tor motor electrical connector. additional information, refer to Door
Window Motor Initialization in this section.

9. Detach the front door window regulator

and motor from the door panel.
• Loosen the bolts.

10. Remove the front door window regulator

and motor.

Installation
1. To install, reverse the removal procedure.

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501-11-62 Glass, Frames and Mechanisms 501-11-62

REMOVAL AND INSTALLATION

Rear Door Window Regulator (42 338 0)

Removal
1. Remove the rear door window glass. For
additional information, refer to Rear Door
Window Glass in this section.
2. Detach the rear door window regulator
from the door panel.
• Loosen the bolts.

3. Remove the rear door window regulator.

Installation
1. To install, reverse the removal procedure.

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501-11-63 Glass, Frames and Mechanisms 501-11-63

REMOVAL AND INSTALLATION

Rear Door Window Regulator and Motor (42 338 0)

Removal
1. Remove the rear door window glass. For
additional information, refer to Rear Door
Window Glass in this section.
2. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
3. Detach the rear door window regulator
from the door panel.
1. Loosen the bolts.
2. Remove the bolt.

4. Remove the rear door window regulator

and motor.
• Disconnect the electrical connector.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Door
Window Motor Initialization in this section.

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501-12-1 Instrument Panel and Console 501-12-1

SECTION 501-12 Instrument Panel and Console

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-12-2

REMOVAL AND INSTALLATION

Instrument Panel .......................................................................................... (43 644 0) 501-12-3

Floor Console ............................................................................................... (43 814 0) 501-12-10
Overhead Console........................................................................................ (43 813 0) 501-12-12

08/2002 2003.0 Mondeo

501-12-2 Instrument Panel and Console 501-12-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Instrument panel support bracket retaining screws 5 – 44
Instrument panel support bracket retaining nut 7 – 62
Instrument panel side retaining bolts 9 – 80
Passenger air bag module to cross-vehicle beam 10 – 89
bolts
Floor console retaining bolts 4 – 35

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501-12-3 Instrument Panel and Console 501-12-3

REMOVAL AND INSTALLATION

Instrument Panel (43 644 0)

REMOVAL AND INSTALLATION

5. Detach the damper from the glove

compartment.
General Equipment 1. Open the glove compartment to access the
damper.
Audio unit removal tools 2. Push the top of the damper away from the
glove compartment.

Removal
All Vehicles
1. Remove the floor console. For additional
information, refer to Floor Console in this
section.
2. Remove the steering column. For
additional information, refer to Section
211-04.
Vehicles with 2.5L or diesel engine
3. Remove the driver side lower footwell trim.

6. Fully open the glove compartment.

• Press the sides of the glove compartment
towards the center to release the glove
compartment stops.

All vehicles
4. Remove the passenger side lower footwell
trim.

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501-12-4 Instrument Panel and Console 501-12-4

REMOVAL AND INSTALLATION (Continued)

7. Remove the glove compartment. 10. Detach the glove compartment light
• Detach the hinges. switch electrical connector from the
lower instrument panel.

8. Detach the glove compartment latch from

the instrument panel. 11. Detach the driver and passenger footwell
light from the lower instrument panel (If
equipped).

9. Detach the glove compartment light and

remove the glove compartment latch.
12. Detach the data link connector (DLC)
from the driver side lower instrument
panel.

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501-12-5 Instrument Panel and Console 501-12-5

REMOVAL AND INSTALLATION (Continued)

13. Detach the internal temperature sensor 15. CAUTION: The passenger air bag
from the driver side lower instrument module retaining bolts must only be
panel (if equipped). used three times.
NOTE: After removal, stamp the passenger air
bag module retaining bolts with a center punch to
indicate usage.
Detach the passenger air bag module
from the cross-vehicle beam.

14. Disconnect the passenger air bag module

electrical connectors.

16. Using the audio unit removal tools, de-

tach the audio unit from the instrument
panel.

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501-12-6 Instrument Panel and Console 501-12-6

REMOVAL AND INSTALLATION (Continued)

17. Disconnect the electrical connectors and 20. Detach the heater control trim panel from
remove the audio unit. the instrument panel.
1. Remove the retaining screws.
2. Detach the retaining clips.

18. Detach the accessory switches from the

heater control trim panel.
21. Disconnect the liftgate release switch
electrical connector.

19. Remove the heater control trim panel

accessory switches.
• Disconnect the electrical connectors. 22. Disconnect the heated front seats electri-
cal connectors.

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501-12-7 Instrument Panel and Console 501-12-7

REMOVAL AND INSTALLATION (Continued)

23. Disconnect the auxiliary climate control 26. Disconnect the instrument cluster lamp
electrical connectors. electrical connector.

24. Remove the heater control trim panel. 27. Remove the keyless entry antenna.
• Disconnect the clock electrical connector. 1. Detach the windshield register from the
instrument panel.
2. Disconnect the keyless entry antenna elec-
trical connector.

25. Disconnect the instrument cluster

electrical connector.
1. Release the locking tang.
2. Disconnect the electrical connector. 28. Remove the instrument panel support
bracket retaining screws.

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501-12-8 Instrument Panel and Console 501-12-8

REMOVAL AND INSTALLATION (Continued)

29. Remove the instrument panel support 33. Remove the instrument panel side trim
bracket retaining nut. panels

30. Detach the instrument panel from the 34. Remove the instrument panel side retain-
cross-vehicle beam. ing bolts (left-hand side shown, right-
hand side similar).

31. Remove the A-pillar trim panels. For

additional information, refer to Section 35. CAUTION: The instrument cluster
501-05. must be kept upright to avoid silicone
32. Detach the weatherstrips from the A- liquid leaking from the guages.
pillars.
Remove the instrument panel.

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501-12-9 Instrument Panel and Console 501-12-9

REMOVAL AND INSTALLATION (Continued)

Vehicles with automatic transaxle

36. Move the selector lever to the "P"
position.

Installation
1. To install, reverse the removal procedure.

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501-12-10 Instrument Panel and Console 501-12-10

REMOVAL AND INSTALLATION

Floor Console (43 814 0)

Removal 5. Remove the floor console trim panel.

Vehicles with automatic transaxle
1. Move the automatic transaxle selector
lever to the "N" position.
All vehicles
2. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
Vehicles with 4-speed automatic transaxle
3. Remove the automatic transaxle selector
lever trim panel.

Vehicles with manual transaxle

6. Remove the gearshift lever boot.

Vehicles with 5-speed automatic transaxle

4. Remove the automatic transaxle selector
lever trim panel.

7. Remove the insulation pad.

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501-12-11 Instrument Panel and Console 501-12-11

REMOVAL AND INSTALLATION (Continued)

All vehicles 11. Detach the floor console from the floor
8. Remove the floor console side trim panels. panel.
1. Remove the retaining screw. 1. Remove the retaining screws.
2. Detach the retaining clips. 2. Remove the retaining bolts.

9. Detach the ashtray and cup holder assem- 12. Remove the floor console.
bly from the floor console. • Fully raise the parking brake lever.

10. Remove the ashtray and cup holder Vehicles with automatic transaxle
assembly. 13. Move the automatic transaxle selector
• Disconnect the cigar lighter electrical con- lever to the "P" position.
nector.

Installation
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-12-12 Instrument Panel and Console 501-12-12

REMOVAL AND INSTALLATION

Overhead Console (43 813 0)

Removal Vehicles with roof opening panel

4. Remove the overhead console.
All vehicles
1. Disconnect the battery ground cable. For 1. Turn the front retaining clips 90 degrees.
additional information, refer to Section 2. Lower the front of the overhead console.
414-01. 3. Detach the rear retaining clips.
2. Using a suitable screwdriver, detach the 4. Disconnect the power roof opening panel
interior lamp from the overhead console. control switch electrical connector.

3. Disconnect the electrical connectors and

remove the interior lamp.

5. Remove the power roof opening panel

control switch.

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501-12-13 Instrument Panel and Console 501-12-13

REMOVAL AND INSTALLATION (Continued)

Vehicles without roof opening panel 8. Remove the overhead console.

6. Open the storage compartment. 1. Lower the rear of the overhead console.
2. Detach the front retaining clips.

7. CAUTION: To avoid damage, the

storage compartment must only be 9. Remove the storage compartment cover.
pulled downwards enough to detach • Detach the hook loop tape.
the retaining clips.
NOTE: The rear of the overhead console is held
in position by the storage compartment cover
retaining clips.
Detach the storage compartment from the
storage compartment cover.
1. Pull the storage compartment downwards.
2. Using a suitable screwdriver, detach the
storage compartment cover retaining clips.

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501-12-14 Instrument Panel and Console 501-12-14

REMOVAL AND INSTALLATION (Continued)

Vehicles with telematics Installation
10. CAUTION: The microphone has two Vehicles with telematics
installation positions, one is for left-
hand drive vehicles and one for right- 1. CAUTION: Make sure the microphone
hand drive vehicles. To aid is installed in the correct position.
installation, make a note of the Install the microphone.
position of the microphone.
1. Install the microphone foam pad.
Remove the microphone. 2. Attach the microphone to the overhead
1. Detach the adhesive tape from the console.
electrical connector and the wiring harness. 3. Attach the microphone electrical connector
2. Detach the microphone electrical connector to the overhead console.
from the overhead console. 4. Attach the adhesive tape to the electrical
3. Detach the microphone from the overhead connector and the wiring harness.
console.
4. Remove the microphone foam pad.

Vehicles with roof opening panel

2. Install the power roof opening panel
control switch.

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501-12-15 Instrument Panel and Console 501-12-15

REMOVAL AND INSTALLATION (Continued)

3. Install the overhead console. 5. CAUTION: Avoid attaching the hook

loop tape when attaching the storage
1. Connect the power roof opening panel compartment cover retaining clips.
control switch electrical connector.
2. Attach the rear retaining clips. Install the storage compartment cover and
the overhead console.
3. Raise the front of the overhead console.
1. Attach the front retaining clips.
4. Turn the front retaining clips 90 degrees.
2. Push the rear of the overhead console
upwards to attach the storage
compartment cover retaining clips.
3. Push the overhead console upwards to at-
tach the hook loop tape.

6. Close the storage compartment.

All vehicles
7. Connect the interior lamp electrical con-
nectors.

Vehicles without roof opening panel

4. NOTE: Do not attach the storage compartment
cover hook loop tape at this stage.
Position the storage compartment cover
through the overhead console opening.

8. Attach the interior lamp to the overhead

console.
9. Connect the battery ground cable. For
additional information, refer to Section
414-01.
10. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-14-1 Handles, Locks, Latches and Entry Systems 501-14-1

SECTION 501-14 Handles, Locks, Latches and Entry

Systems
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-14-2

DESCRIPTION AND OPERATION

Handles, Locks, Latches and Entry Systems ..................................................................... 501-14-3

DIAGNOSIS AND TESTING

Locks, Latches and Entry Systems.................................................................................... 501-14-5

Inspection and Verification ............................................................................................... 501-14-5

GENERAL PROCEDURES

Remote Transmitter Programming................................................................ (41 004 0) 501-14-6

REMOVAL AND INSTALLATION

Front Door Latch........................................................................................... (41 351 0) 501-14-7

Rear Door Latch ........................................................................................... (41 352 0) 501-14-14
Liftgate Latch................................................................................................ (41 666 0) 501-14-20

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501-14-2 Handles, Locks, Latches and Entry Systems 501-14-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Door latch retaining screws 5 - 44
Hood latch retaining bolts 7 - 62
Liftgate latch retaining screws 8 - 71
Tailgate latch retaining screws 8 - 71
Luggage compartment lid latch retaining screws 8 - 71

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501-14-3 Handles, Locks, Latches and Entry Systems 501-14-3

DESCRIPTION AND OPERATION

Handles, Locks, Latches and Entry Systems

DESCRIPTION AND OPERATION

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501-14-4 Handles, Locks, Latches and Entry Systems 501-14-4

DESCRIPTION AND OPERATION (Continued)

Item Part Description

Number
1 Front and rear door lock ac-
tuator RH
2 Ignition lock cylinder and ig-
nition key
3 Hood latch
4 Liftgate exterior release
switch
5 Luggage compartment lid
latch actuator
6 Keyless entry remote trans-
mitter
7 Front and rear door lock ac-
tuator LH

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501-14-5 Handles, Locks, Latches and Entry Systems 501-14-5

DIAGNOSIS AND TESTING

Locks, Latches and Entry Systems

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 501-14 for

schematic and connector information.

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
– Misaligned door(s), – Fuse(s)
hood, liftgate, – Wiring harness
tailgate, luggage
– Electrical
compartment and
connector(s)
hood
– Door latch
– Door latch(es)
actuator(s)
– Liftgate exterior
– Remote transmitter
release switch
batteries
– Actuating rod(s)
– Vehicle battery
– Exterior door
– Remote transmitter
handle(s)
– Door lock switch(es)
– Door latch remote
control(s) – Generic electronic
module (GEM)
– Door lock cylinder
– Cable(s)
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 cause is not visually evident, verify the
symptom and refer to WDS to diagnose the
system.

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501-14-6 Handles, Locks, Latches and Entry Systems 501-14-6

GENERAL PROCEDURES

Remote Transmitter Programming (41 004 0)

GENERAL PROCEDURES

1. NOTE: A maximum of four keyless entry

remote transmitters can be programmed to the
generic electronic module (GEM).
Programming must be done at the same time
for all the transmitters.
NOTE: To enter programming mode, first make
sure that the vehicle battery is fully charged and
the anti-theft system is not armed or triggered (if
equipped).
Close all doors and fasten the safety belts
to make sure conflicting chimes do not
sound during programming.
2. Turn the ignition switch from position I to
position II at least four times in six
seconds.
3. Turn the ignition switch to position I.
4. The GEM is now in the learning mode.
5. Press and hold one of the buttons on the
remote transmitter until a chime sounds.
This indicates a new transmitter code has
been successfully received.
6. After each successful programming,
another 10 second learning mode is
automatically entered, up to a maximum of
four times.
7. To program additional transmitters, repeat
step 5.
8. The system will leave the learning mode
after the ignition switch is turned to
position III, or if no new transmitter is
programmed during the 10 seconds, or if
four remote transmitters have been
programmed.
9. NOTE: An incorrect programming procedure
does not affect the stored codes.
After successful programming, only the
new programmed transmitters will be
accepted.
10. Test all the programmed transmitters, by
activating and deactivating the
locking/unlocking functions.

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501-14-7 Handles, Locks, Latches and Entry Systems 501-14-7

REMOVAL AND INSTALLATION

Front Door Latch (41 351 0)

REMOVAL AND INSTALLATION

Removal 4. NOTE: Do not touch the adhesive surface as

re-bonding will be impaired.
1. NOTE: Pull out and hold the exterior front door
handle. Detach the door water shield from the front
door panel.
Remove the exterior front door handle ac-
cess hole grommet and loosen the exterior
front door handle retaining screw.

5. Detach the front door latch remote control

from the door panel.
2. Remove the exterior front door handle.
1. Slide the exterior front door handle to
release.
2. Pull the exterior front door handle to re-
move.

6. Disconnect the front door lock actuator

electrical connector.

3. Remove the front door trim panel. For

additional information, refer to Section
501-05.

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501-14-8 Handles, Locks, Latches and Entry Systems 501-14-8

REMOVAL AND INSTALLATION (Continued)

7. Loosen the exterior front door handle rein- 10. Remove the front door latch security
forcement plate retaining screw. shield retaining screws (driver side
shown).

8. Detach the exterior front door handle

reinforcement plate. 11. Remove the front door latch security
1. Slide the exterior front door handle shield retaining screw and remove the
reinforcement plate toward the front of the front door latch security shield (driver
door panel. side shown).
2. Dislocate the exterior front door handle re-
inforcement plate locking tangs from the
door panel.

12. Remove the driver side door lock

cylinder connecting rod.
1. Rotate the clip counterclockwise to release
9. Remove the front door latch. the connecting rod.
2. Pull the connecting rod up.

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501-14-9 Handles, Locks, Latches and Entry Systems 501-14-9

REMOVAL AND INSTALLATION (Continued)

13. Remove the exterior front door handle 15. Remove the front door latch remote
reinforcement plate connecting rod. control cable from the front door latch.
• Rotate the connecting rod 90 degrees. 1. Detach the front door latch remote control
outer cable.
2. Rotate the front door latch remote control
cable clockwise.
3. Remove the front door latch.

14. Remove the exterior front door handle

adjustment clip from the door handle
reinforcement plate.
• Discard the clip.

Installation
1. Install the front door latch remote control
cable onto the front door latch.
1. Attach the front door latch remote control
cable to the front door latch.
2. Rotate the front door latch remote control
cable counter clockwise.
3. Attach the front door latch remote control
outer cable.

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501-14-10 Handles, Locks, Latches and Entry Systems 501-14-10

REMOVAL AND INSTALLATION (Continued)

2. NOTE: Install a new exterior front door handle 4. Install the driver side door lock cylinder
adjustment clip. connecting rod.
NOTE: Do not lock the adjustment clip into place 1. Install the connecting rod.
at this stage. 2. Rotate the clip to lock the connecting rod in
Install the exterior front door handle ad- position.
justment clip and connecting rod.

5. Install the front door latch security shield.

3. Install the exterior front door handle rein-
forcement plate connecting rod.

6. Install the front door latch security shield

retaining screws.

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501-14-11 Handles, Locks, Latches and Entry Systems 501-14-11

REMOVAL AND INSTALLATION (Continued)

7. NOTE: Do not tighten the front door latch 10. Attach the exterior front door handle
retaining screws at this stage. reinforcement plate.
Install the front door latch. 1. Locate the exterior front door handle
reinforcement plate locking tangs onto the
door panel.
2. Slide the exterior front door handle rein-
forcement plate into position.

8. Attach the front door latch remote control

to the door panel.

11. Install the exterior front door handle.

1. Locate the exterior front door handle into
the front door panel.
2. Slide the exterior front door handle forward
to install it onto the door handle reinforce-
ment plate.

9. Connect the front door lock actuator elec-

trical connector.

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501-14-12 Handles, Locks, Latches and Entry Systems 501-14-12

REMOVAL AND INSTALLATION (Continued)

12. Tighten the exterior front door handle re- 15. NOTE: Two audible clicks should be heard
taining screw. when the door latch lever is closed completely.
Close the front door latch lever in the
jaws of the door latch.

13. Install the exterior front door handle re-

taining screw.
16. Lock and unlock the front door latch
using the rocker lever on the front door
latch remote control handle.
17. Open the front door latch using the exte-
rior front door handle. The door latch
should open at approximately 75% of
handle full travel (22mm). The exterior
front door handle should have between 5-
6 mm of travel after the front door latch
has released.

14. Press the exterior front door handle ad-

justment clip to set the latch position.

18. NOTE: If further adjustment of the door latch

is required, a new door latch connecting rod
adjustment clip must be installed.
If the door latch does not open correctly
remove the door latch and reset the
exterior front door handle adjustment
clip.

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501-14-13 Handles, Locks, Latches and Entry Systems 501-14-13

REMOVAL AND INSTALLATION (Continued)

19. Tighten the front door latch retaining

screws.

20. Attach the door water shield.

21. Install the front door trim panel. For
additional information, refer to Section
501-05.

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501-14-14 Handles, Locks, Latches and Entry Systems 501-14-14

REMOVAL AND INSTALLATION

Rear Door Latch (41 352 0)

Removal 4. Remove the exterior rear door handle.

1. Remove the rear door trim panel. For 1. Slide the exterior rear door handle
additional information, refer to Section backward to release.
501-05. 2. Pull the exterior rear door handle to re-
2. NOTE: Do not touch the adhesive surface as move.
re-bonding will be impaired.
Detach the door water shield from the rear
door panel.

5. Detach the rear door latch remote control

from the door panel.

3. NOTE: Pull out and hold the exterior rear door

handle.
Remove the exterior rear door handle ac-
cess hole grommet and loosen the exterior
rear door handle retaining screw.

6. Disconnect the rear door lock actuator

electrical connector.

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501-14-15 Handles, Locks, Latches and Entry Systems 501-14-15

REMOVAL AND INSTALLATION (Continued)

10. Detach the rear door latch from the

7. Loosen the exterior rear door handle rein-
exterior rear door handle reinforcement
forcement plate retaining screw.
plate.
1. Press the clip to release.
2. Detach the door latch from the exterior rear
door handle reinforcement plate.

8. Detach the exterior rear door handle

reinforcement plate.
1. Slide the exterior rear door handle
reinforcement plate toward the front of the
door panel. 11. Remove the exterior rear door handle re-
inforcement plate.
2. Dislocate the exterior rear door handle
reinforcement plate locking tangs from the
door panel.

12. Remove the rear door latch connecting

rod.
9. Remove the rear door latch. • Rotate the rear door latch connecting rod
90 degrees counterclockwise.

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501-14-16 Handles, Locks, Latches and Entry Systems 501-14-16

REMOVAL AND INSTALLATION (Continued)

Installation
13. Release the rear door latch connecting
rod adjustment clip. 1. Install the rear door latch remote control
• Discard the clip. cable onto the rear door latch.
1. Attach the rear door latch remote control
cable to the rear door latch.
2. Rotate the rear door latch remote control
cable counter clockwise.
3. Attach the rear door latch remote control
outer cable.

14. Remove the rear door latch

1. Detach the rear door latch remote control
outer cable.
2. Rotate the rear door latch remote control
clockwise.
3. Remove the rear door latch.
2. NOTE: Install a new exterior rear door handle
adjustment clip.
NOTE: Do not lock the adjustment clip into place
at this stage.
Install the rear door latch connecting rod.
• Rotate the rear door latch connecting rod
90 degrees clockwise.

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501-14-17 Handles, Locks, Latches and Entry Systems 501-14-17

REMOVAL AND INSTALLATION (Continued)

3. Install the exterior rear door handle rein- 6. Connect the rear door lock actuator elec-
forcement plate to the connecting rod. trical connector.

4. Install the exterior rear door handle rein- 7. Attach the rear door latch remote control
forcement plate to the rear door latch. to the door panel.

5. NOTE: Do not tighten the door screws at this 8. Install the exterior rear door handle
stage. reinforcement plate.
Install the rear door latch. 1. Locate the exterior rear door handle
reinforcement plate locking tangs onto the
door panel.
2. Slide the exterior rear door handle rein-
forcement plate into position.

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501-14-18 Handles, Locks, Latches and Entry Systems 501-14-18

REMOVAL AND INSTALLATION (Continued)

9. Tighten the exterior rear door handle rein- 12. Install the exterior rear door handle ac-
forcement plate retaining screw. cess hole grommet.

10. Install the exterior rear door handle. 13. Press the door latch connecting rod ad-
1. Install the exterior rear door handle. justment clip to set the latch position.
2. Slide the exterior rear door handle forward
to install it onto the exterior rear door han-
dle reinforcement plate.

14. NOTE: Two audible clicks should be heard

when the door latch lever is closed completely.
Close the door latch lever.
11. Install the exterior rear door handle and
install the exterior rear door handle re-
taining screw.

15. Lock and unlock the door latch using the

rocker lever on the door latch remote
control.

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501-14-19 Handles, Locks, Latches and Entry Systems 501-14-19

REMOVAL AND INSTALLATION (Continued)

16. Open the door latch using the exterior

rear door handle. The door latch should
open at approximately 75% of handle full
travel (22mm). The exterior rear door
handle should have between 5-6 mm of
travel after the door latch has released.

17. NOTE: If further adjustment of the door latch

is required, a new door latch connecting rod
adjustment clip must be installed.
If the door latch does not open correctly
remove the door latch and reset the door
latch connecting rod adjustment clip.
18. Tighten the door screws.

19. Attach the door water shield.

20. Install the rear door trim panel. For
additional information, refer to Section
501-05.

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501-14-20 Handles, Locks, Latches and Entry Systems 501-14-20

REMOVAL AND INSTALLATION

Liftgate Latch (41 666 0)

Removal 4. Detach the liftgate latch release cable from

the retaining clip.
1. Remove the liftgate latch trim panel.

5. Detach the liftgate latch release cable from

2. Remove the liftgate trim panel retaining
the liftgate lock cylinder retaining clip.
screws.

6. Detach the liftgate latch release cable from

3. Remove the liftgate trim panel.
the liftgate lock cylinder.

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501-14-21 Handles, Locks, Latches and Entry Systems 501-14-21

REMOVAL AND INSTALLATION (Continued)

7. Disconnect the liftgate latch electrical

connector.

8. Remove the liftgate latch.

Installation
1. To install, reverse the removal procedure.

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501-16-1 Wipers and Washers 501-16-1

SECTION 501-16 Wipers and Washers

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-16-2

DIAGNOSIS AND TESTING

Wipers and Washers ......................................................................................................... 501-16-3

Inspection and Verification ............................................................................................... 501-16-3
Symptom Chart ................................................................................................................ 501-16-3
Pinpoint Tests .................................................................................................................. 501-16-5
Component checks........................................................................................................... 501-16-38

GENERAL PROCEDURES

Windshield Wiper Blade and Pivot Arm Adjustment........................................................... 501-16-40

REMOVAL AND INSTALLATION

Windshield Wiper Motor................................................................................ (32 524 0) 501-16-41

Rear Window Wiper Motor............................................................................ (32 530 0) 501-16-43

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501-16-2 Wipers and Washers 501-16-2

SPECIFICATIONS

Front Wiper Blade and Pivot Arm Adjustment (Left-hand drive vehicles)
Angle between windshield and wiper arm (driver side ) 6 degrees
Angle between windshield and wiper arm (passenger side) 5 degrees

Front Wiper Blade and Pivot Arm Adjustment (Right-hand drive vehicles)
Angle between windshield and wiper arm (driver side ) -6 degrees
Angle between windshield and wiper arm (passenger side) -5 degrees

Rear Wiper Blade and Pivot Arm Adjustment (Hatchback)

Angle between rear window and wiper arm -6 degrees

Rear Wiper Blade and Pivot Arm Adjustment (Wagon)

Angle between rear window and wiper arm -5.5 degrees

Torque Specifications
Description Nm lb-ft lb-in
Windshield wiper arm retaining nut 22 16 -
Windshield wiper motor and linkage retaining bolts 8 - 71
Windshield wiper crank retaining nut 26 19 -
Windshield wiper motor retaining bolts 8 - 71
Rear window wiper arm retaining nut 14 10 -
Rear window wiper motor retaining bolts 7 - 62

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501-16-3 Wipers and Washers 501-16-3

DIAGNOSIS AND TESTING

Wipers and Washers

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 501-16 for

schematic and connector information.
Inspection and Verification
Special Tool(s)
1. Verify the customer concern.
Digital multimeter 2. Visually inspect for obvious signs of
105-R0051 or a comparable mechanical or electrical damage.
device
Visual Check
Mechanical Electrical
• Wiper blade(s). • Fuse(s).
Terminal probe kit • Wiper arm pivot • Wiring harness.
29-011 A shaft. • Electrical
• Washer fluid connector(s).
reservoir • Washer pump(s)
• Hose(s). • Wiper motor(s).
• Washer nozzles.
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 persists, verify the symptom
and continue with the symptom chart
Symptom Chart

Condition Possible Sources Action

• Windscreen wipers are inopera- • Fuse(s). • GO to Pinpoint Test A
tive (washer system is OK) • Circuit(s).
• Central Junction Box (CJB).
• Wash/wipe switch
• Windscreen wiper is perma- • Fuse(s). • GO to Pinpoint Test B
nently on • Circuit(s).
• Windscreen wiper relay.
• Wash/wipe switch
• Windscreen wiper motor.
• Central Junction Box (CJB.
• GEM.
• Fast wipe speed does not work • Circuit(s). • GO to Pinpoint Test C
correctly (intermittent mode OK) • Wash/wipe switch
• Windscreen wiper motor.
• Slow wipe speed does not work • Wash/wipe switch • CHECK the wash/wipe switch
correctly (intermittent mode OK) according to the component
check in the Wiring Diagrams,
RENEW as necessary.
CHECK the operation of the
system .

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501-16-4 Wipers and Washers 501-16-4

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• Intermittent function not working • Circuit(s). • GO to Pinpoint Test D
properly (fast/slow wipe OK) • Windscreen wiper relay.
• Wash/wipe switch
• GEM.
• Central Junction Box (CJB).
• Windscreen wiper park position • Circuit(s). • GO to Pinpoint Test E
is incorrect • Windscreen wiper relay.
• Wash/wipe switch
• Windshiel wiper motor.
• Central Junction Box (CJB).
• Windscreen wipers do not work • Circuit(s). • REFER to Section 419-10.
correctly when the washer sys- • GEM.
tem is operated
• Wash/wipe function inoperative • Circuit(s). • GO to Pinpoint Test F
• Wash/wipe switch
• Washer pump inoperative • Circuit(s). • GO to Pinpoint Test G
• Washer pump motor
• Wash/wipe switch
• Rear window wiper is inopera- • Circuit(s). • GO to Pinpoint Test H
tive • Rear window wiper relay.
• Rear window wiper motor.
• Wash/wipe switch
• GEM.
• Rear window wiper is perma- • Circuit(s). • GO to Pinpoint Test I
nently on • Rear window wiper relay.
• Rear window wiper motor.
• Wash/wipe switch
• GEM.
• Rear wiper park position is in- • Circuit(s). • GO to Pinpoint Test J
correct • Rear window wiper motor.
• Central Junction Box (CJB).
• Rear wiper does not work cor- • Circuit(s). • REFER to Section 419-10.
rectly when the washer system • GEM.
is operated
• Headlamp washer system does • Circuit(s). • GO to Pinpoint Test K
not operate correctly • Headlamp washer relay.
• Headlamp washer pump motor
• Headlamp washer system per- • Circuit(s). • GO to Pinpoint Test L
manently switched on • Headlamp washer relay.
• Windscreen washer nozzle • Circuit(s). • GO to Pinpoint Test M
heater inoperative • Windscreen washer nozzle
heater

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501-16-5 Wipers and Washers 501-16-5

DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests
PINPOINT TEST A: WINDSCREEN WIPER INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FUSE F94 (CJB)
1 Key in OFF position.
2 CHECK Fuse F94 (CJB).
3 Check fuse F94 (20 A).
• Is the fuse OK?
→ Yes
GO to A2
→ No
INSTALL a new fuse F94 (20 A). If the fuse
blows again, LOCATE and REPAIR the
short using the Wiring Diagrams. CHECK
the operation of the system .
A2: CHECK CIRCUIT BETWEEN FUSE F94 (CJB) AND THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Connect Fuse F94 (CJB).
3 Disconnect Wash/wipe switch C530.
4 Key in ON position.
5 Measure the voltage between the wash/wipe
switch, connector C530, pin 6, circuit 15-KA19
(GN/OG), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to A4
→ No
GO to A3
A3: CHECK THE CENTRAL JUNCTION BOX (CJB)
1 Key in OFF position.
2 Disconnect CJB C500.
3 Key in ON position.

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501-16-6 Wipers and Washers 501-16-6

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the CJB, con-
nector C500, pin 10, circuit 15-KA19 (GN/OG),
CJB side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR the open circuit 15-KA19 (GN/OG)
between the CJB and the wash/wipe switch
using the Wiring Diagrams. CHECK the
operation of the system.
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
A4: CHECK THE GROUND CONNECTION OF THE WINDSCREEN WIPER MOTOR
1 Key in OFF position.
2 Disconnect Windscreen wiper motor C144.
3 Measure the resistance between windscreen
wiper motor, connector C144, pin 5, circuit 31-
KA8 (BK), harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to A5
→ No
REPAIR the open circuit 31-KA8 (BK/BU)
using the Wiring Diagrams. CHECK the
operation of the system.
A5: CHECK THE OPERATION OF THE WASH/WIPE SWITCH
1 Check the wash/wipe switch according to the
component check in the Wiring Diagrams.
• Is the switch OK?

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501-16-7 Wipers and Washers 501-16-7

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
CHECK the windscreen wiper motor accord-
ing to the component check at the end of
this section, RENEW as necessary.
CHECK the operation of the system.
→ No
RENEW the wash/wipe switch. CHECK the
operation of the system.
PINPOINT TEST B: WINDSCREEN WIPERS ARE PERMANENTLY SWITCHED ON
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: DETERMINE THE WINDSCREEN WIPER OPERATING SPEED
1 Key in ON position.
2 Switch off the WINDSCREEN WIPERS.
3 Check the wipers.
• Do the windscreen wipers operate at fast
speed?
→ Yes
GO to B2
→ No
GO to B4
B2: CHECK THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Key in ON position.
4 Check the wipers.
• Are the wipers permanently switched on?
→ Yes
GO to B3
→ No
CHECK the wash/wipe switch according to
the component check in the Wiring Dia-
grams, RENEW as necessary. CHECK the
operation of the system.
B3: CHECK CIRCUIT 32-KA11 (WH/BK) FOR SHORT TO BATTERY VOLTAGE
1 Key in OFF position.
2 Disconnect Windscreen wiper motor C144.
3 Key in ON position.

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501-16-8 Wipers and Washers 501-16-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between windscreen
wiper motor, connector C144, pin 1, circuit 32-
KA11 (WH/BK) harness side and ground.

• Is battery voltage indicated?

→ Yes
LOCATE and REPAIR short to battery volt-
age in circuit 32-KA11 (WH/BK) using the
Wiring Diagrams. CHECK the operation of
the system.
→ No
CHECK the windscreen wiper motor accord-
ing to the component check at the end of
this section, RENEW as necessary.
CHECK the operation of the system.
B4: READ OUT THE FAULT MEMORY
1 Key in OFF position.
2 Connect the diagnostic tool.
3 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.
→ No
GO to B5
B5: CHECK THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Key in ON position.
4 Check the wipers.
• Do the windscreen wipers operate with slow
speed?
→ Yes
LOCATE and REPAIR the short to battery
voltage in circuit 32-KA10 (WH/GN) be-
tween the wash/wipe switch and the wiper
motor using the Wiring Diagrams. CHECK
the operation of the system.
→ No

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501-16-9 Wipers and Washers 501-16-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to B6
B6: CHECK VOLTAGE AT CIRCUIT 32-KA19 (WH/BK)
1 Measure the voltage between wiper switch,
connector C530, pin 7, circuit 32-KA19
(WH/BK), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to B7
→ No
CHECK the wash/wipe switch according to
the component check in the Wiring Dia-
grams, RENEW as necessary. CHECK the
operation of the system.
B7: CHECK CIRCUIT 32-KA19 (WH/BK) FOR SHORT TO BATTERY VOLTAGE
1 Key in OFF position.
2 Disconnect Central Junction Box (CJB) C501.
3 Key in ON position.
4 Measure the voltage between the wash/wipe
switch, connector C530, pin 7, circuit 32-KA19
(WH/BK), wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
LOCATE and REPAIR short to battery volt-
age in circuit 32-KA19 (WH/BK) using the
Wiring Diagrams. CHECK the operation of
the system.
→ No
GO to B8

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501-16-10 Wipers and Washers 501-16-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B8: CHECK THE CENTRAL JUNCTION BOX (CJB).
1 Key in OFF position.
2 Disconnect Windscreen wiper relay C917.
3 Key in ON position.
4 Measure the voltage between the windscreen
wiper relay, connector C917, pin 3, CJB side
and ground.

• Is battery voltage indicated?

→ Yes
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
→ No
GO to B9
B9: CHECK THE CENTRAL JUNCTION BOX (CJB) FOR A SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between the wind-
screen wiper relay, connector C917, pin 1,
CJB side and ground.

• Is the resistance less than 2 ohms?

→ Yes
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
→ No
GO to B10

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501-16-11 Wipers and Washers 501-16-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
B10: CHECK THE CONTROL CIRCUIT OF THE WINDSCREEN WIPER RELAY FOR SHORT TO
GROUND
1 Measure the resistance between CJB, connec-
tor C501, pin 12, circuit 31S-KA14 (BK/GN),
harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to B11
→ No
CHECK the wiper relay according to the
component check in the Wiring Diagrams,
RENEW as necessary. CHECK the opera-
tion of the system.
B11: CHECK CIRCUIT 31S-KA14 (BK/GN) FOR SHORT TO GROUND
1 Disconnect GEM module C430.
2 Key in ON position.
3 Measure the resistance between CJB, connec-
tor C501, pin 12, circuit 31S-KA14 (BK/GN),
harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
LOCATE and REPAIR short to ground in
circuit 31S-KA14 (BK/GN) using the Wiring
Diagrams. CHECK the operation of the
system.
→ No
RENEW the generic electronic module
(GEM) CHECK the operation of the sys-
tem.

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501-16-12 Wipers and Washers 501-16-12

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: FAST WIPE SPEED DOES NOT WORK CORRECTLY (INTERMITTENT MODE
OK)
CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK WINDSCREEN WIPER MOTOR
1 Key in OFF position.
2 Disconnect Windscreen wiper motor C144.
3 Key in ON position.
4 Switch on the wipers at FAST SPEED.
5 Measure the voltage between windscreen
wiper motor, connector C144, pin 1, circuit 32-
KA11 (WH/BK), harness side and ground.

• Is battery voltage indicated?

→ Yes
CHECK and if necessary RENEW the wind-
screen wiper motor. CHECK the operation
of the system.
→ No
GO to C2
C2: CHECK CIRCUIT 32-KA11 (WH/BK)
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Measure resistance between windscreen wiper
motor, connector C144, pin 1, circuit 32-KA11
(WH/BK), wiring harness side and wash/wipe
switch, connector C530, pin 8, circuit 32-KA11
(WH/BK), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK the wash/wipe switch according to
the component check in the Wiring Dia-
grams, RENEW as necessary. CHECK the
operation of the system.

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501-16-13 Wipers and Washers 501-16-13

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR the open circuit 32-KA11 (WH/BK)
using the Wiring Diagrams. CHECK the
operation of the system.
PINPOINT TEST D: INTERMITTENT FUNCTION NOT WORKING PROPERLY (FAST AND SLOW
WIPE OK)
CONDITIONS DETAILS/RESULTS/ACTIONS
D1: READ OUT THE FAULT MEMORY
1 Connect the diagnostic tool.
2 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.
→ No
GO to D2
D2: CHECK THE VOLTAGE AT THE WINDSCREEN WIPER RELAY (PIN 2)
1 Key in OFF position.
2 Disconnect Windscreen wiper relay C917.
3 Key in OFF position.
4 Measure the voltage between the windscreen
wiper relay, connector C917, pin 2, CJB side
and ground.

• Is battery voltage indicated?

→ Yes
GO to D3
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.

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501-16-14 Wipers and Washers 501-16-14

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
D3: CHECK THE VOLTAGE AT THE WINDSCREEN WIPER RELAY (PIN 5)
1 Measure the voltage between the windscreen
wiper relay, connector C917, pin 5, CJB side
and ground.

• Is battery voltage indicated?

→ Yes
GO to D4
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
D4: CHECK THE CONTROL CIRCUIT OF THE WINDSCREEN WIPER RELAY FOR SHORT TO
BATTERY VOLTAGE
1 Measure the voltage between the windscreen
wiper relay, connector C917, pin 1, CJB side
and ground.

• Is battery voltage indicated?

→ Yes
LOCATE and REPAIR the short to battery
voltage in the circuit between the wiper re-
lay and the generic electronic module
(GEM) using the Wiring Diagrams, if nec-
essary RENEW the CJB. CHECK the op-
eration of the system.
→ No
GO to D5
D5: CHECK THE WINDSCREEN WIPER RELAY
1 Check the windscreen wiper relay according to
the component check in the Wiring Diagrams.
• Is the relay OK?

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501-16-15 Wipers and Washers 501-16-15

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to D6
→ No
RENEW the wiper relay. CHECK the op-
eration of the system.
D6: CHECK THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Key in ON position.
4 Check the wash/wipe switch according to the
component check in the Wiring Diagrams.
• Is the switch OK?
→ Yes
GO to D7
→ No
RENEW the wash/wipe switch. CHECK the
operation of the system.
D7: CHECK THE CONTROL CIRCUIT OF THE WINDSCREEN WIPER RELAY FOR OPEN
CIRCUIT
1 Key in OFF position.
2 Connect Wash/wipe switch C530.
3 Disconnect GEM module C430.
4 Measure the resistance between the wind-
screen wiper relay, connector C917, pin 1,
CJB side and the GEM, connector C430, pin
21, circuit 31S-KA14 (BK/GN), wiring harness
side.

• Is the resistance less than 2 ohms?

→ Yes
Intermittent mode inoperative: GO to D8
Intermittent speed cannot be controlled (po-
tentiometer): GO to D9
→ No
REPAIR the open circuit between the wind-
screen wiper relay and the GEM using the
Wiring Diagrams, if necessary RENEW the
CJB. CHECK the operation of the system.
D8: CHECK CONTROL CIRCUIT FOR INTERMITTENT OPERATION
1 Disconnect GEM module C429.
2 Key in ON position.
3 Switch on the INTERMITTENT WIPE.

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501-16-16 Wipers and Washers 501-16-16

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the GEM, con-
nector C429, pin 4, circuit 8-KA19 (WH/BK),
wiring harness side and ground.

• Does the meter display battery voltage?

→ Yes
RENEW the generic electronic module
(GEM) CHECK the operation of the sys-
tem.
→ No
REPAIR the open circuit 8-KA19 (WH/BK)
between the wash/wipe switch and the
GEM using the Wiring Diagrams. CHECK
the operation of the system.
D9: CHECK THE CONTROL CIRCUIT FOR VARIABLE INTERMITTENT OPERATION
1 Key in ON position.
2 Switch on INTERMITTENT WIPE mode and
turn the variable wipe function from position 1
to position 6.
3 Measure the voltage between the GEM, con-
nector C430, pin 4, circuit 8-KA18 (WH), wir-
ing harness side and ground.

• Is a voltage measured?
→ Yes
RENEW GEM. CHECK the operation of
the system.
→ No
REPAIR the open circuit 8-KA18 (WH) be-
tween the wash/wipe switch and the GEM
using the Wiring Diagrams. CHECK the
operation of the system.

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501-16-17 Wipers and Washers 501-16-17

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E: WINDSCREEN WIPER PARK POSITION IS INCORRECT

CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE WINDSCREEN WIPER RELAY
1 Key in OFF position.
2 Disconnect Windscreen wiper relay C917.
3 Using a fused test cable (20 A) at the wind-
screen wiper relay, bridge connector C917, pin
3 and pin 4, CJB side.

4 Key in ON position.
5 Operate SINGLE WIPE mode.
6 Check the wipers.
• Do the wipers return to the park position?
→ Yes
RENEW the windscreen wiper relay.
CHECK the operation of the system.
→ No
GO to E2
E2: CHECK THE OPERATION OF WIPER INTERMITTENT MODE
1 Key in OFF position.
2 Connect Windscreen wiper relay C917.
3 Key in ON position.
4 Switch on the INTERMITTENT WIPE.
5 Check the wipers.
• Are the wipers operating in intermittent mode?
→ Yes
GO to E4
→ No
GO to E3
E3: CHECK THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Check the wash/wipe switch according to the
component check in the Wiring Diagrams.
• Is the switch OK?
→ Yes

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501-16-18 Wipers and Washers 501-16-18

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit between the wind-
screen wiper relay, connector C917, pin 3
and the wash/wipe switch using the Wiring
Diagrams, if necessary RENEW the CJB.
CHECK the operation of the system.
→ No
RENEW the wash/wipe switch. CHECK the
operation of the system.
E4: CHECK THE VOLTAGE AT THE WINDSCREEN WIPER MOTOR
1 Key in OFF position.
2 Disconnect Windscreen wiper motor C144.
3 Key in ON position.
4 Measure the voltage between windscreen
wiper motor, connector C144, pin 4, circuit 15-
KA9 (GN/RD), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to E5
→ No
REPAIR the open circuit between fuse F94
(CJB) and the wiper motor, connector
C144, pin 4, circuit 15-KA9 (GN/RD), using
the Wiring Diagrams, if necessary RENEW
the CJB. CHECK the operation of the sys-
tem.
E5: CHECK THE WINDSCREEN WIPER MOTOR
1 Key in OFF position.
2 Check the windscreen wiper motor according
to the component check at the end of this sec-
tion.
• Is the wiper motor in order?
→ Yes
REPAIR the open circuit between the wiper
relay, connector C917, pin 4, and the wiper
motor, connector C144, pin 3, circuit 32-KA9
(WH/BU), using the Wiring Diagrams, if
necessary RENEW the CJB. CHECK the
operation of the system.
→ No

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501-16-19 Wipers and Washers 501-16-19

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
RENEW the wiper motor CHECK the op-
eration of the system.
PINPOINT TEST F: WASH/WIPE FUNCTION INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
F1: CHECK THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 CARRY OUT a component check on the
wash/wipe switch, as specified in this section.
• Is the switch OK?
→ Yes
REPAIR the open circuit 31-KA19 (BK) us-
ing the Wiring Diagrams. CHECK the op-
eration of the system.
→ No
RENEW the wash/wipe switch. CHECK the
operation of the system.
PINPOINT TEST G: WASHER PUMP INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
G1: CHECK CIRCUIT 32-KA34 (WH/BK)
1 Key in OFF position.
2 Disconnect Washer pump motor C184.
3 Key in ON position.
4 Measure the voltage between the washer
pump motor, connector C184, pin 1, circuit 32-
KA34 (WH/BK), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to G3
→ No
GO to G2
G2: CHECK CIRCUIT 32-KA34 (WH/BK)
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Key in ON position.

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501-16-20 Wipers and Washers 501-16-20

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between the
wash/wipe switch C530, pin 4, circuit 32-KA34
(WH/BK), wiring harness side and washer
pump motor, connector C184, pin 1, circuit 32-
KA34 (WH/BK), wiring harness side.

• Is the resistance less than 2 ohms?

→ Yes
CHECK the wash/wipe switch according to
the component check in the Wiring Dia-
grams, RENEW as necessary. CHECK the
operation of the system.
→ No
REPAIR the open circuit 32-KA34 (WH/BK)
using the Wiring Diagrams. CHECK the
operation of the system.
G3: CHECK CIRCUIT 33-KA34 (YE/BK)
1 Measure the voltage between the washer
pump motor, connector C184, pin 2, circuit 33-
KA34 (YE/BK), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
RENEW the washer pump motor. CHECK
the operation of the system.
→ No
REPAIR the open circuit 33-KA34 (WH/BK)
or 33-KA1 (YE/RD) using the Wiring Dia-
grams. CHECK the operation of the sys-
tem.

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501-16-21 Wipers and Washers 501-16-21

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H: REAR WINDOW WIPER IS INOPERATIVE

CONDITIONS DETAILS/RESULTS/ACTIONS
H1: CHECK FUSE F90 (CJB)
1 Key in OFF position.
2 CHECK Fuse F90 (CJB).
3 Check fuse F90 (15 A).
• Is the fuse OK?
→ Yes
GO to H2
→ No
INSTALL a new fuse F90 (15 A). If the fuse
blows again, LOCATE and REPAIR the
short using the Wiring Diagrams. CHECK
the operation of the system.
H2: CHECK THE VOLTAGE AT FUSE F90 (CJB)
1 Key in OFF position.
2 Connect Fuse F90 (15 A).
3 Key in ON position.
4 Measure the voltage between fuse F90 (CJB)
and ground.
• Is battery voltage indicated?
→ Yes
GO to H3
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
H3: READ OUT THE FAULT MEMORY
1 Key in OFF position.
2 Connect the diagnostic tool.
3 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system
→ No
GO to H4
H4: CHECK VOLTAGE AT THE REAR WINDOW WIPER RELAY (PIN 2)
1 Key in OFF position.
2 Disconnect Rear window wiper relay C916.
3 Key in ON position.

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501-16-22 Wipers and Washers 501-16-22

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between the rear wiper
relay, connector C916, pin 2, CJB side and
ground.

• Is battery voltage indicated?

→ Yes
GO to H5
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
H5: CHECK VOLTAGE AT THE REAR WINDOW WIPER RELAY (PIN 5)
1 Measure the voltage between the rear wiper
relay, connector C916, pin 5, CJB side and
ground.

• Is battery voltage indicated?

→ Yes
GO to H6
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
H6: CHECK THE OPERATING CIRCUIT OF THE REAR WIPER RELAY
1 Key in OFF position.

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501-16-23 Wipers and Washers 501-16-23

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Using a fused test cable (15 A) at the rear
wiper relay, bridge connector C916, pin 3 and
pin 5, CJB side.

3 Key in ON position.
4 Check the wipers.
• Do the rear wipers operate?
→ Yes
GO to H10
→ No
GO to H7
H7: CHECK THE VOLTAGE AT THE REAR WIPER MOTOR (CIRCUIT 32-KA28 WH/RD)
1 Key in OFF position.
2 Connect Rear window wiper motor C745.
3 Using a fused test cable (15 A) at the rear
wiper relay, bridge connector C916, pin 3 and
pin 5, CJB side.

4 Key in ON position.
5 Measure the voltage between the rear wiper
motor, connector C745, pin 2, circuit 32-KA28
(WH/RD), wiring harness side and ground.

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501-16-24 Wipers and Washers 501-16-24

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is battery voltage indicated?

→ Yes
GO to H8
→ No
REPAIR the open circuit between the wiper
relay and the wiper motor using the Wiring
Diagrams, if necessary RENEW the CJB.
CHECK the operation of the system.
H8: CHECK THE VOLTAGE AT THE REAR WIPER MOTOR (CIRCUIT 29-KA28 OG/BU)
1 Measure the voltage between rear window
wiper motor, connector, C745, pin 1, circuit
29-KA28 (OG/BU), harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to H9
→ No
REPAIR the open circuit between fuse F90
(CJB) and the wiper motor using the Wiring
Diagrams, if necessary RENEW the CJB.
CHECK the operation of the system.
H9: CHECK THE GROUND CONNECTION OF THE REAR WINDOW WIPER MOTOR
1 Key in OFF position.
2 Measure the resistance between the rear win-
dow wiper motor, connector C745, pin 3, cir-
cuit 31-KA28 (BK), wiring harness side and
ground.

• Is the resistance less than 2 ohms?

→ Yes

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501-16-25 Wipers and Washers 501-16-25

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Check the wiper motor according to the
component check at the end of this section
and RENEW as necessary. CHECK the
operation of the system.
→ No
REPAIR the open circuit between the wiper
motor and solder point S518 (ground G300)
using the Wiring Diagrams. CHECK the
operation of the system.
H10: CHECK THE REAR WIPER RELAY
1 Key in OFF position.
2 Check the rear wiper relay according to the
component check in the Wiring Diagrams.
• Is the relay OK?
→ Yes
GO to H11
→ No
RENEW the rear wiper relay. CHECK the
operation of the system.
H11: CHECK THE WASH/WIPE SWITCH
1 Connect Rear window wiper relay..
2 Disconnect Wash/wipe switch C530.
3 Check the wash/wipe switch according to the
component check in the Wiring Diagrams.
• Is the switch OK?
→ Yes
GO to H12
→ No
RENEW the wash/wipe switch. CHECK the
operation of the system.
H12: CHECK CIRCUIT 32-KA35 (WH/RD)
1 Connect Wash/wipe switch C530.
2 Disconnect GEM module C430.
3 Key in ON position.
4 Switch on the REAR WINDOW WIPER.
5 Measure the voltage between the GEM, con-
nector C430, pin 3, circuit 32-KA35 (WH/RD),
wiring harness side and ground.

• Is battery voltage indicated?

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501-16-26 Wipers and Washers 501-16-26

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to H13
→ No
REPAIR the open circuit 32-KA35 (WH/RD)
between the wash/wipe switch and the
GEM using the Wiring Diagrams. CHECK
the operation of the system.
H13: CHECK CIRCUIT 32-KA6 (WH/BK)
1 Measure the voltage between the GEM, con-
nector C430, pin 2, circuit 32-KA6 (WH/BK),
wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to H14
→ No
REPAIR the open circuit 32-KA6 (WH/BK)
between the wash/wipe switch and the
GEM using the Wiring Diagrams. CHECK
the operation of the system.
H14: CHECK THE CONTROL CIRCUIT OF THE REAR WIPER RELAY
1 Using a fused test cable (10A) bridge between
the GEM, connector C430, pin 17, circuit 31S-
KA29 (BKYE), wiring harness side and ground.

2 Check the rear wiper.

• Does the rear wiper operate?
→ Yes
RENEW THE GEM. CHECK the operation
of the system.
→ No

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501-16-27 Wipers and Washers 501-16-27

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit 31S-KA29 (BK/YE)
between the wiper relay and the GEM using
the Wiring Diagrams, if necessary RENEW
the CJB. CHECK the operation of the sys-
tem.
PINPOINT TEST I: REAR WINDOW WIPER IS PERMANENTLY ON
CONDITIONS DETAILS/RESULTS/ACTIONS
I1: READ OUT THE FAULT MEMORY
1 Connect the diagnostic tool.
2 Check the system using WDS.
• Are any trouble codes (DTCs) displayed?
→ Yes
RESOLVE the faults according to the WDS
instructions. CLEAR the fault memory and
CHECK the operation of the system.
→ No
GO to I2
I2: NARROW DOWN THE LOCATION OF THE SHORT TO BATTERY VOLTAGE
1 Key in OFF position.
2 Disconnect Rear window wiper relay C916.
3 Key in ON position.
4 Check the wipers.
• Are the rear wipers operating continuously?
→ Yes
GO to I3
→ No
GO to I4
I3: CHECK THE OPERATING CIRCUIT OF THE REAR WIPER RELAY FOR SHORT TO BATTERY
VOLTAGE
1 Key in OFF position.
2 Disconnect Rear window wiper motor C745.
3 Key in ON position.
4 Measure the voltage between the rear wiper
relay, connector C916, pin 3, circuit 32-KA28
(WH/RD), CJB side and ground.

• Is battery voltage indicated?

→ Yes

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501-16-28 Wipers and Washers 501-16-28

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and REPAIR short to battery volt-
age in the circuit between the wiper relay
and the wiper motor, if necessary, REPAIR
the CJB. CHECK the operation of the sys-
tem.
→ No
Check the wiper motor according to the
component check at the end of this section
and RENEW as necessary. CHECK the
operation of the system.
I4: CHECK THE CONTROL CIRCUIT OF THE WIPER RELAY FOR SHORT TO GROUND
1 Measure the voltage at the rear wiper relay,
connector C916, between pin 1 and pin 2, CJB
side.

• Is voltage displayed?
→ Yes
GO to I5
→ No
RENEW the rear wiper relay. CHECK the
operation of the system.
I5: CHECK THE CONTROL CIRCUIT OF THE WIPER RELAY
1 Key in OFF position.
2 Disconnect GEM module C430.
3 Measure the voltage at the rear wiper relay,
connector C916, between pin 1 and pin 2, CJB
side.

• Is voltage displayed?
→ Yes

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501-16-29 Wipers and Washers 501-16-29

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and REPAIR short to ground in the
circuit between the wiper relay and the
GEM, if necessary, REPAIR the CJB.
CHECK the operation of the system.
→ No
GO to I6
I6: CHECK THE VOLTAGE AT THE GEM (CONTROL CIRCUIT FOR REAR WIPER)
NOTE: Wash/wipe switch to the OFF position.
1 Key in ON position.
2 Measure the voltage between the GEM, con-
nector C430, pin 3, circuit 32-KA35 (WH/RD),
wiring harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to I7
→ No
RENEW the generic electronic module
(GEM) CHECK the operation of the sys-
tem.
I7: CHECK THE WASH/WIPE SWITCH
1 Key in OFF position.
2 Disconnect Wash/wipe switch C530.
3 Key in ON position.
4 Measure the voltage between the GEM, con-
nector C430, pin 3, circuit 32-KA35 (WH/RD),
wiring harness side and ground.

• Is battery voltage indicated?

→ Yes

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501-16-30 Wipers and Washers 501-16-30

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
LOCATE and REPAIR short to battery volt-
age in circuit 32-KA35 (WH/RD). CHECK
the operation of the system.
→ No
CHECK the wash/wipe switch according to
the component check in the Wiring Dia-
grams, RENEW as necessary. CHECK the
operation of the system.
PINPOINT TEST J: REAR WIPER PARK POSITION IS INCORRECT
CONDITIONS DETAILS/RESULTS/ACTIONS
J1: CHECK CIRCUIT 29-KA28 (OG/BU)
1 Key in OFF position.
2 Disconnect Rear window wiper motor C745.
3 Key in ON position.
4 Measure the voltage between the rear window
wiper motor, connector, C745, pin 1, circuit
29-KA28 (OG/BU), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
CHECK the rear wiper motor according to
the component check at the end of this sec-
tion and RENEW as necessary. CHECK
the operation of the system.
→ No
GO to J2
J2: CHECK THE CENTRAL JUNCTION BOX (CJB)
1 Key in OFF position.
2 Disconnect Central Junction Box (CJB) C506.
3 Key in ON position.

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501-16-31 Wipers and Washers 501-16-31

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the voltage between CJB, connector
C506, pin 16, CJB side and ground.

• Is battery voltage indicated?

→ Yes
REPAIR the open circuit 29-KA28 (OG/BU)
using the Wiring Diagrams. CHECK the
operation of the system.
→ No
CHECK the CJB and RENEW as neces-
sary. CHECK the operation of the system.
PINPOINT TEST K: HEADLAMP WASHER SYSTEM DOES NOT OPERATE CORRECTLY
CONDITIONS DETAILS/RESULTS/ACTIONS
K1: CHECK FUSE F22 (BJB)
1 Key in OFF position.
2 CHECK Fuse F22 (BJB).
3 Check fuse F22 (20 A).
• Is the fuse OK?
→ Yes
GO to K2
→ No
INSTALL a new fuse F22 (20 A). If the fuse
blows again, LOCATE and REPAIR the
short using the Wiring Diagrams. CHECK
the operation of the system.
K2: CHECK CIRCUIT 31-KA21 (BK)
1 Key in OFF position.
2 Connect Fuse F22 (BJB).
3 Disconnect Headlamp washer pump motor
C145.

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501-16-32 Wipers and Washers 501-16-32

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between the headlamp
washer pump motor, connector C145, pin 2,
circuit 31-KA21 (BK), wiring harness side and
ground.

• Is the resistance less than 2 ohms?

→ Yes
GO to K3
→ No
REPAIR the open circuit 31-KA21 (BK) us-
ing the Wiring Diagrams. CHECK the op-
eration of the system.
K3: CHECK CIRCUIT 15S-KA21 (GN/YE)
1 Key in ON position.
2 Switch on the dipped beam.
3 Switch on the WINDSCREEN WASHER
SYSTEM.
4 Measure the voltage between the headlamp
washer pump motor, connector C145, pin 1,
circuit 15S-KA21 (GN/YE), wiring harness side
and ground.

• Is battery voltage indicated?

→ Yes
RENEW the headlamp washer pump motor.
CHECK the operation of the system.
→ No
GO to K4
K4: CHECK CIRCUIT 15S-KA21 (GN/YE)
1 Key in OFF position.
2 Disconnect Headlamp washer relay C439.

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501-16-33 Wipers and Washers 501-16-33

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between the headlamp
washer pump motor, connector C145, pin 1,
circuit 15S-KA21 (GN/YE), wiring harness side
and the headlamp washer relay, connector
C439, pin 3, circuit 15S-KA21 (GN/YE), wiring
harness side.

• Is the resistance less than 2 ohms?

→ Yes
GO to K5
→ No
REPAIR the open circuit 15S-KA21 (GN/YE)
using the Wiring Diagrams. CHECK the
operation of the system.
K5: CHECK CIRCUIT 30-KA23 (RD)
1 Measure the voltage between the headlamp
washer relay, connector C439, pin 5, circuit
30-KA23 (RD), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to K6
→ No
REPAIR the open circuit 30-KA23 (RD) us-
ing the Wiring Diagrams. CHECK the op-
eration of the system.
K6: CHECK CIRCUIT 15S-KA22 (GN/BU)
1 Key in ON position.
2 Switch on the dipped beam.

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501-16-34 Wipers and Washers 501-16-34

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the voltage between the headlamp
washer relay, connector C439, pin 4, circuit
15S-KA22 (GN/BU), wiring harness side and
ground.

• Is battery voltage indicated?

→ Yes
GO to K7
→ No
REPAIR the open circuit 15S-KA22
(GN/BU) using the Wiring Diagrams.
CHECK the operation of the system.
K7: CHECK THE GROUND CONNECTION OF THE HEADLAMP WASHER RELAY
1 Key in OFF position.
2 Measure the resistance between the headlamp
washer relay, connector C439, pin 2, circuit
31-KA22 (BK), wiring harness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
RENEW the headlamp washer relay.
CHECK the operation of the system.
→ No
REPAIR the open circuit 31-KA22 (BK) be-
tween the headlamp washer relay and sol-
der point S315 (ground G104) using the
Wiring Diagrams. CHECK the operation of
the system.
PINPOINT TEST L: HEADLAMP WASHER SYSTEM PERMANENTLY SWITCHED ON
CONDITIONS DETAILS/RESULTS/ACTIONS
L1: CHECK THE HEADLAMP WASHER RELAY
1 Key in OFF position.

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501-16-35 Wipers and Washers 501-16-35

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Headlamp washer relay C439.
3 Key in ON position.
4 CHECK the headlamp washer pump.
• Is the headlamp washer pump permanently
switched on?
→ Yes
LOCATE and REPAIR the short to battery
voltage in circuit 15S-KA21 (GN/YE) using
the Wiring Diagrams. CHECK the opera-
tion of the system.
→ No
RENEW the headlamp washer relay.
CHECK the operation of the system.
PINPOINT TEST M: WINDSCREEN WASHER NOZZLE HEATER INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
M1: CHECK THE WINDSCREEN WASHER NOZZLE HEATER
1 Key in ON position.
2 Determine if the windscreen washer nozzle
heater is inoperative.
• Is the left-hand windscreen washer nozzle
heater inoperative?
→ Yes
GO to M2
→ No
The right-hand windscreen washer nozzle
heater is inoperative: GO to M4
M2: CHECK CIRCUIT 15S-HB13 (GN/BU)
1 Key in OFF position.
2 Disconnect Left-hand windscreen washer noz-
zle heater, C165.
3 Key in ON position.
4 Measure the voltage between the left-hand
windscreen washer nozzle heater, connector
C165, pin 2, circuit 15S-HB13 (GN/BU), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to M3
→ No

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501-16-36 Wipers and Washers 501-16-36

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit 15S-HB13
(GN/BU) using the Wiring Diagrams.
CHECK the operation of the system.
M3: CHECK CIRCUIT 31-HB13 (BK)
1 Key in OFF position.
2 Measure the resistance between the left-hand
windscreen washer nozzle heater, connector
C165, pin 1, circuit 31-HB13 (BK), wiring har-
ness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
RENEW the left-hand windscreen washer
nozzle heater. CHECK the operation of the
system.
→ No
REPAIR the open circuit 31-HB13 (BK) us-
ing the Wiring Diagrams. CHECK the op-
eration of the system.
M4: CHECK CIRCUIT 15S-HB26 (GN/RD)
1 Key in OFF position.
2 Disconnect Right-hand windscreen washer
nozzle heater, C166.
3 Key in ON position.
4 Measure the voltage between the right-hand
windscreen washer nozzle heater, connector
C166, pin 2, circuit 15S-HB26 (GN/RD), wiring
harness side and ground.

• Is battery voltage indicated?

→ Yes
GO to M5
→ No

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501-16-37 Wipers and Washers 501-16-37

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the open circuit 15S-HB21
(GN/RD) using the Wiring Diagrams.
CHECK the operation of the system.
M5: CHECK CIRCUIT 31-HB26 (BK)
1 Key in OFF position.
2 Measure the resistance between the right-hand
windscreen washer nozzle heater, connector
C166, pin 1, circuit 31-HB26 (BK), wiring har-
ness side and ground.

• Is the resistance less than 2 ohms?

→ Yes
RENEW the right-hand windscreen washer
nozzle heater. CHECK the operation of the
system.
→ No
REPAIR the open circuit 31-HB26 (BK) us-
ing the Wiring Diagrams. CHECK the op-
eration of the system.

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501-16-38 Wipers and Washers 501-16-38

DIAGNOSIS AND TESTING

2. Check the wiper motor in the FAST WIPE

setting (for test set-up see diagram
Component checks VFE0030700).
• Connect the positive terminal of the power
supply to the positive terminal of the digital
Windscreen wiper motor.
multimeter.
• Switch off the ignition. • Connect the negative terminal of the power
• Pull out the plugs. supply to the wiper motor, pin 5, or to the
• Connect the test cables as described below: housing of the wiper motor.
• Connect an external 12 V DC supply for a • Connect the negative terminal of the digital
minimum current of 10 A (alternatively use a multimeter to the wiper motor, pin 1. The
fused auxiliary cable) to the vehicle battery. wiper motor runs at fast speed.
1. Check the wiper motor in the SLOW WIPE Measure the current.
setting. Is the reading on the digital multimeter approx.
2.2 A?
If yes, GO TO 3.
If not, RENEW the wiper motor.
3. Check the wiper motor in the PARK
POSITION

• Connect the positive terminal of the power

supply to the positive terminal of the digital
multimeter.
• Connect the negative terminal of the power
supply to the wiper motor, pin 5, or to the
housing of the wiper motor.
• Connect the negative terminal of the digital Measure the resistance at the wiper motor
multimeter to the wiper motor, pin 2. The between pin 3 and pin 5 (or the housing of the
wiper motor runs at slow speed. wiper motor).
Measure the current.
Is the resistance less than 2 ohms?
Is the reading on the digital multimeter approx.
If yes, GO TO 4.
1,5 A?
If not, GO TO 4 and REPEAT this step. (If it is
If yes, GO TO 2.
still not as specified, RENEW the wiper motor.)
If not, RENEW the wiper motor.
4. Check the park position of the wiper motor
NOTE: The wiper motor is not in the park
position.

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501-16-39 Wipers and Washers 501-16-39

DIAGNOSIS AND TESTING (Continued)

• Connect the positive terminal of the power

supply to the positive terminal of the digital
multimeter.
• Connect the negative terminal of the power
supply to the wiper motor, pin 3.
• Connect the negative terminal of the digital
multimeter to the wiper motor, pin 2. The
wiper motor runs at slow speed.
Measure the current.
Is the reading on the digital multimeter approx.
1,5 A?
If yes, GO TO 2.
• Connect the positive terminal of the power If not, RENEW the wiper motor.
supply to the wiper motor, pin 4. 2. Check the park position of the wiper motor.
• Connect the negative terminal of the power NOTE: The wiper motor is not in the park
supply to the wiper motor, pin 2. position.
• Connect a bridging cable to the wiper motor
between pins 3 and 5.
Check the position
Does the wiper motor return to the PARK
POSITION?
If yes, the wiper motor is OK.
If not, RENEW the wiper motor.

Rear window wiper motor.

• Switch off the ignition.
• Separate the connector.
• Connect the test cables as described below:
• Connect an external 12 V DC supply for a
• Connect the positive terminal of the power
minimum current of 10 A (alternatively use a
supply to the wiper motor, pin 1.
fused auxiliary cable) to the vehicle battery.
• Connect the negative terminal of the power
1. Check the wiper motor in the SLOW WIPE
supply to the wiper motor, pin 3.
setting.
Check the position
Does the wiper motor return to the PARK
POSITION?
If yes, the wiper motor is OK.
If not, RENEW the wiper motor.

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501-16-40 Wipers and Washers 501-16-40

GENERAL PROCEDURES

Windshield Wiper Blade and Pivot Arm Adjustment

GENERAL PROCEDURES

4. NOTE: Lift the special tool away from the glass

when correcting the angle, in order to prevent
damage.
Special Tool(s)
Using the special tool, check and adjust
Aligner, Wiper Arm the wiper arm. For additional information,
501-027 (32-006) refer to Specifications in this section.
• Using an open-ended wrench on the spe-
cial tool, adjust the angle.

Adjustment
1. CAUTION: Make sure that the wiper
motor is in the park position.
Remove the wiper blade.
2. Insert the wiper arm in the special tool and
place the special tool on the windshield.
3. NOTE: All three support points of the special
tool must be in contact with the glass.
Using the special tool, read off the angle
between the wiper arm and the windshield. 5. Remove the special tool.
6. Install the wiper blade.

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501-16-41 Wipers and Washers 501-16-41

REMOVAL AND INSTALLATION

Windshield Wiper Motor (32 524 0)

REMOVAL AND INSTALLATION

Removal Vehicles equipped with anti-theft alarm horn with

integrated battery
All vehicles
3. Disconnect the anti-theft alarm horn con-
1. CAUTION: Ensure that the wiper motor nector.
is in the park position.
Remove the windshield wiper arms.

All vehicles
4. Remove the windshield wiper motor and
linkage.
2. Remove the cowls. .
• Disconnect the windshield wiper motor
• Pull the cowls from the retaining groove. connector.

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501-16-42 Wipers and Washers 501-16-42

REMOVAL AND INSTALLATION (Continued)

5. Mark position of the windshield wiper link- Installation
age crank arm in relation to the windshield
wiper bracket. 1. CAUTION: Move the wiper motor to
park position before installing the
wiper arms.
Install the components in the reverse
order.

6. Remove the nut of the windshield wiper

linkage crank arm.

7. Remove the windshield wiper motor.

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501-16-43 Wipers and Washers 501-16-43

REMOVAL AND INSTALLATION

Rear Window Wiper Motor (32 530 0)

Removal Wagon
3. Remove the liftgate trim panel.
All vehicles
1. NOTE: Make sure that the rear window wiper
motor is in the park position.
Remove the rear window wiper arm
(wagon shown).

All vehicles
4. Disconnect the rear window wiper motor
electrical connector (wagon shown).

Hatchback
2. Remove the liftgate trim panel.

5. Remove the rear window wiper motor

(wagon shown).

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501-16-44 Wipers and Washers 501-16-44

REMOVAL AND INSTALLATION (Continued)

Installation
1. To install, reverse the removal procedure.

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501-17-1 Roof Opening Panel 501-17-1

SECTION 501-17 Roof Opening Panel

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-17-2

DESCRIPTION AND OPERATION

Roof Opening Panel .......................................................................................................... 501-17-3

DIAGNOSIS AND TESTING

Roof Opening Panel .......................................................................................................... 501-17-6

Inspection and Verification ............................................................................................... 501-17-6
Symptom Chart ................................................................................................................ 501-17-6
Pinpoint Tests .................................................................................................................. 501-17-7
Component Tests ............................................................................................................. 501-17-11

GENERAL PROCEDURES

Water Drainage System Check and Water Leak Corrections........................ (41 002 0) 501-17-12
Roof Opening Panel Alignment..................................................................... (41 113 0) 501-17-13
Roof Opening Panel Motor Initialization............................................................................. 501-17-15
Updating Roof Opening Panel Motor Initialization............................................................. 501-17-15
Initial Roof Opening Panel Motor Initialization .................................................................. 501-17-15
Erasing Roof Opening Panel Motor Initialization............................................................... 501-17-15

REMOVAL AND INSTALLATION

Roof Opening Panel ..................................................................................... (41 114 0) 501-17-16

Roof Opening Panel Glass ................................................................................................ 501-17-18
Roof Opening Panel Motor ........................................................................... (33 786 0) 501-17-20

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501-17-2 Roof Opening Panel 501-17-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Roof opening panel frame retaining bolts 9 - 80
Roof opening panel motor retaining bolts 3 - 27
Roof opening panel glass retaining bolts 3 - 27

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501-17-3 Roof Opening Panel 501-17-3

DESCRIPTION AND OPERATION

Roof Opening Panel

DESCRIPTION AND OPERATION

Front Drain Hoses drain hose, the inertia fuel shut-off (IFS) switch
mounting bracket must be detached from the A-
The front drain hoses are connected to the roof
pillar. Both drain hoses are equipped with a
opening panel frame and routed to the underside
rubber drain bung that automatically releases
of the vehicle through the A-pillar. They are
pressure and allows the drain hose to empty.
removed through the opening behind the A-pillar
lower trim panel. To remove the left-hand side

5-door vehicles, and the D-pillar on the wagon.

Item Part Description They are located by a rubber grommet at the
Number base of the pillar. The drain hoses are secured to
the vehicle by three retaining clips on 4-door and
1 Front drain hose 5-door vehicles, and 6 retaining clips on the
Rear Drain Hoses wagon. Both drain hoses are equipped with a
rubber drain bung that automatically releases
The rear drain hoses are connected to the roof
pressure and allows the drain hose to empty.
opening panel frame and routed to the underside
of the vehicle through the C-pillar on 4-door and

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501-17-4 Roof Opening Panel 501-17-4

DESCRIPTION AND OPERATION

4-door and 5-Door

Item Part Description

Item Part Description Number
Number
2 Rear drain hose
1 Retaining clip

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501-17-5 Roof Opening Panel 501-17-5

DESCRIPTION AND OPERATION

Wagon

Item Part Description

Number
1 Retaining clip
2 Rear drain hose

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501-17-6 Roof Opening Panel 501-17-6

DIAGNOSIS AND TESTING

Roof Opening Panel

DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 501-17 for Mechanical Electrical

schematic and connector information. Roof opening panel Fuse(s)
Seal(s) Electrical connector(s)
Weatherstrip
Inspection and Verification
Alignment
1. Verify the customer concern. 3. If an obvious cause for an observed or
2. Visually inspect for obvious signs of reported concern is found, correct the cause
mechanical or electrical damage. (if possible) before proceeding to the next
step.
Visual Inspection Chart 4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• The roof opening panel leaks • Drain tubes. • CHECK the drain tubes for
blockage or obstruction. CARRY
OUT the Water Drainage Sys-
tem Check and Water Leak Cor-
rections. REFER to Water
Drainage System Check and
Water Leak Corrections in this
section.
• The roof opening panel rattles • Headliner. • CHECK the headliner for secu-
rity. REFER to Section 501-
05.
• Guides and track. • CHECK for worn or damaged
• Motor. components. CARRY OUT the
Roof Opening Panel Alignment.
REFER to Roof Opening Panel
Alignment in this section.
• The roof opening panel is noisy • Guides and track. • CHECK for worn or damaged
during operation • Motor. components. CARRY OUT the
Roof Opening Panel Alignment.
REFER to Roof Opening Panel
Alignment in this section.
• The roof opening panel does not • Switch. • CARRY OUT the Roof Opening
open or close Panel Control Switch Compo-
nent Test in this section.
• Motor. • CARRY OUT the Roof Opening
Panel Motor Synchronization.
REFER to Roof Opening Panel
Motor Synchronization in this
section.
• Circuits. • GO to Pinpoint Test A
• The roof opening panel shows • Motor. • GO to Pinpoint Test B
unexpected bounce back at high • Circuits.
speed.

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501-17-7 Roof Opening Panel 501-17-7

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• The roof opening panel does not • Guides and track. • CHECK for worn or damaged
stop in flush from any position • Motor. components. CARRY OUT the
Roof Opening Panel Alignment.
REFER to Roof Opening Panel
Alignment in this section.

Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements.
PINPOINT TEST A: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR VOLTAGE TO THE ROOF OPENING PANEL CONTROL SWITCH
1 Key in ON position.
2 CHECK the operation of the roof opening
panel control switch lamp.
• Does the roof opening panel control switch
lamp illuminate?
→ Yes
GO to A2
→ No
GO to A6
A2: CHECK THE SUPPLY VOLTAGE TO THE ROOF OPENING PANEL CONTROL UNIT, CIRCUIT
29-AG12 (OG/BK)
1 Key in OFF position.
2 Disconnect Fuse 73 (20A).
3 Disconnect Roof Opening Panel Control Unit
C525.
4 Connect Fuse 73 (20A).
5 Measure the voltage between the roof opening
panel control unit C525 pin 1, circuit 29-AG12
(OG/BK), harness side and ground.

• Is the voltage greater than 10 volts?

→ Yes
GO to A3

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501-17-8 Roof Opening Panel 501-17-8

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR circuit 29-AG12 (OG/BK). TEST
the system for normal operation.
A3: CHECK THE ROOF OPENING PANEL CONTROL SWITCH UP/CLOSE GROUND CIRCUIT
1 Operate the roof opening panel control switch
to the UP/CLOSE position and keep it pressed.
2 Measure the resistance between the roof
opening panel control unit C525 pin 9, circuit
31S-AG7A (BK/BU), harness side and ground.

• Is the resistance less than 100 ohms?

→ Yes
GO to A4
→ No
REPAIR circuit 31S-AG7A (BK/BU). TEST
the system for normal operation.
A4: CHECK THE ROOF OPENING PANEL CONTROL SWITCH DOWN/OPEN GROUND CIRCUIT
1 Operate the roof opening panel control switch
to the DOWN/OPEN position and keep it
pressed.
2 Measure the resistance between the roof
opening panel control unit C525 pin 8, circuit
31S-AG7 (BK/BU), harness side and ground.

• Is the resistance less than 100 ohms?

→ Yes
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501-17-9 Roof Opening Panel 501-17-9

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to A5
→ No
REPAIR circuit 31S-AG7 (BK/BU). TEST
the system for normal operation.
A5: CHECK THE ROOF OPENING PANEL CONTROL UNIT GROUND CIRCUIT
1 Measure the resistance between the roof
opening panel control unit C525 pin 10, circuit
31-AG12 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new roof opening panel control
unit. TEST the system for normal operation.
→ No
REPAIR circuit 31-AG12 (BK). TEST the
system for normal operation.
A6: CHECK THE SUPPLY VOLTAGE TO THE ROOF OPENING PANEL CONTROL SWITCH
LAMP, CIRCUIT 15-AG7 (GN/BU)
1 Key in OFF position.
2 Disconnect Roof Opening Panel Control
Switch C522.
3 Key in ON position.
4 Measure the voltage between the roof opening
panel control switch C522 pin 1, circuit 15-AG7
(GN/BU), harness side and ground.

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501-17-10 Roof Opening Panel 501-17-10

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the voltage greater than 10 volts?

→ Yes
GO to A7
→ No
REPAIR circuit 15-AG7 (GN/BU). TEST the
system for normal operation.
A7: CHECK THE ROOF OPENING PANEL CONTROL SWITCH GROUND CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the roof
opening panel control switch C522 pin 6, circuit
31-AG7 (BK), harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
VERIFY the customer concern.
→ No
REPAIR circuit 31-AG7 (BK). TEST the sys-
tem for normal operation.
PINPOINT TEST B: THE ROOF OPENING PANEL SHOWS UNEXPECTED BOUNCE BACK AT
HIGH SPEED
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE OPERATION OF THE MULTIFUNCTION DISPLAY
1 Drive the vehicle.
2 Observe the multi-function display ‘Average
speed’ function.
• Does the display operate correctly?
→ Yes
GO to B2
→ No
REFER to Section 413-01.
B2: CHECK FOR CONTINUITY BETWEEN THE POWERTRAIN CONTROL MODULE (PCM) AND
THE ROOF OPENING PANEL CONTROL UNIT
NOTE: The circuit numbers and wiring colors change at soldered joint S7.
1 Key in OFF position.
2 Disconnect PCM C100.

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501-17-11 Roof Opening Panel 501-17-11

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Install the PCM breakout box.
4 Measure the resistance between powertrain
control module C100 pin 94, circuit 8-GB8
(WH/BU), harness side and the roof opening
panel motor C525 pin 6, circuit 8-GB8
(WH/BU), harness side.
• Is the resistance less than 5 ohms?
→ Yes
INSTALL a new roof opening panel motor.
TEST the system for normal operation.
→ No
REPAIR circuit 8-GB8 (WH/BU). TEST the
system for normal operation.

Component Tests

Roof Opening Panel Control Switch

1. Measure the resistance between the
following:
Roof Opening Panel Control Switch Position Terminals Measurements
Neutral 1-6 GO to Step 2.
Neutral 1-2 Greater than 10,000 ohms
Neutral 1-5 Greater than 10,000 ohms
Neutral 2-6 Greater than 10,000 ohms
Neutral 5-6 Greater than 10,000 ohms
Neutral 6-1 Greater than 10,000 ohms
Fully Up/Close 5-6 Less than 100 ohms
Fully Up/Close 5-1 Greater than 10,000 ohms
Fully Up/Close 5-2 Less than 100 ohms
Fully Up/Close 2-6 Less than 100 ohms
Fully Down/Open 2-6 Less than 100 ohms
Fully Down/Open 2-5 Less than 100 ohms
Fully Down/Open 5-6 Less than 100 ohms
Fully Down/Open 2-1 Greater than 10,000 ohms
2. Apply +12v battery positive to the roof
opening panel control switch C522 pin 1,
component side and 0v battery negative to
the roof opening panel control switch C522
pin 6, component side. The LED should
illuminate. If the LED does not illuminate
install a new roof opening panel control
switch.
3. If the roof opening panel control switch
values are as specified, return to the Pinpoint
Test. If the roof opening panel control switch
values are outside the specified values,
install a new roof opening panel control
switch.

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501-17-12 Roof Opening Panel 501-17-12

GENERAL PROCEDURES

Water Drainage System Check and Water Leak Corrections (41 002 0)
GENERAL PROCEDURES

1. If a drain hose blockage or obstruction is

suspected, check the drain hoses by
pouring 500 ml of water into the drain
trough and checking the flow from under
the vehicle rocker panels. Attempt to clear
any blockage or obstruction using a drain
clearing wire (nylon). If the blockage or
obstruction cannot be cleared the drain
hose must be removed. For additional
information, refer to Drain Hose - Front /
Drain Hose - Rear in this section.
2. If a drain hose leak is suspected the drain
hose must be removed and inspected for
cracks or splits. For additional
information, refer to Drain Hose - Front /
Drain Hose - Rear in this section.

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501-17-13 Roof Opening Panel 501-17-13

GENERAL PROCEDURES

Roof Opening Panel Alignment (41 113 0)

1. NOTE: The roof opening panel must be in the 5. Tighten the rear retaining screws.
closed position for alignment.
Remove the roof opening panel guide arm
covers (if equipped).

6. Adjust the front edge of the roof opening

panel glass.
1. Push the front edge up or down to give the
2. Place a suitable 1.0 - 1.2 mm thick, 150 mm correct alignment (flush to -1 mm).
long plastic spacer between the rear edge 2. Tighten the front retaining screws.
of the roof opening panel glass and the
roof panel opening.
3. Adjust the rear edge of the roof opening
panel glass.
1. Loosen the retaining screws.
2. Push the rear edge up or down to give the
correct alignment (flush to + 1 mm).

7. Install the roof opening panel guide arm

covers (if equipped).

4. Make sure that the roof opening panel

glass is located centrally in the roof panel
opening.

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501-17-14 Roof Opening Panel 501-17-14

GENERAL PROCEDURES (Continued)

8. NOTE: Remove the plastic spacer.
Operate the roof opening panel and check
the alignment.
9. Check the roof opening panel seal for wind
noise and water leaks.

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501-17-15 Roof Opening Panel 501-17-15

GENERAL PROCEDURES

Roof Opening Panel Motor Initialization

NOTE: The roof opening panel alignment must

be carried out prior to carrying out roof opening
Updating Roof Opening Panel Motor panel motor initialization. For additional
Initialization information, refer to Roof Opening Panel
Alignment in this section.
WARNING: The roof opening panel anti- 1. Operate the roof opening panel control
trap function will not operate during the switch to the up/close position.
updating roof opening panel motor
initialization procedure. Make sure that 2. Release the roof opening panel control
the roof opening panel opening is free of switch.
all foreign material. Failure to follow this 3. Operate the roof opening panel control
instruction may result in personal injury. switch to the up/close position again
NOTE: This procedure should only be carried out within 0.5 seconds until the roof opening
when the roof opening panel motor has not been panel stops (one complete cycle).
disconnected.
NOTE: The roof opening panel alignment must
Erasing Roof Opening Panel Motor
be carried out prior to carrying out roof opening
Initialization
panel motor initialization. For additional
information, refer to Roof Opening Panel NOTE: The erasing procedure is to be carried out
Alignment in this section. only when the roof opening panel motor has been
1. Operate the roof opening panel control detached from the roof opening panel.
switch to the up/close position until the NOTE: This procedure must be carried out
roof opening panel is in the fully open/vent before installing a previously used roof opening
position. panel motor.
2. Release the roof opening panel control 1. Connect the roof opening panel motor
switch. electrical connector.
3. Operate the roof opening panel control 2. Operate the roof opening panel control
switch to the up/close position and hold switch to the up/close position until the
for 30 seconds until there is a small roof opening panel motor stops.
movement (approximately 2 mm) and the 3. Release the roof opening panel control
roof opening panel motor stops. switch.
4. Release the roof opening panel control 4. Operate the roof opening panel control
switch. switch again to the up/close position and
5. Operate the roof opening panel control hold for 30 seconds. With the roof opening
switch to the up/close position again panel control switch held, the roof opening
within 0.5 seconds until the roof opening panel motor will rotate in one direction.
panel stops (one complete cycle). 5. Release the roof opening panel control
switch.
6. Operate the roof opening panel control
Initial Roof Opening Panel Motor Initialization switch to the down/open position. If the
WARNING: The roof opening panel anti- roof opening panel motor does not rotate,
trap function will not operate during the the erasing procedure has been carried
updating roof opening panel motor out successfully.
initialization procedure. Make sure that 7. If the roof opening panel motor rotates
the roof opening panel opening is free of (with the roof opening panel control switch
all foreign material. Failure to follow this in the down/open position), repeat the
instruction may result in personal injury. procedure.
NOTE: This procedure must be carried out when
installing any roof opening panel motor or roof
opening panel.

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501-17-16 Roof Opening Panel 501-17-16

REMOVAL AND INSTALLATION

Roof Opening Panel (41 114 0)

REMOVAL AND INSTALLATION

Removal 4. Remove the roof opening panel.

1. NOTE: Make sure the roof opening panel is in • With the aid of another technician, com-
the closed position. press the legs of the retaining clips and
lower the roof opening panel.
Remove the headliner. For additional
information, refer to Section 501-05.
2. Detach the drain hoses from the roof open-
ing panel.

Installation
1. NOTE: The roof opening panel must be
3. Detach the roof opening panel from the correctly located on the retaining clips before
roof panel (12 bolts). tightening the retaining bolts.
NOTE: Do not fully tighten the retaining bolts at
this stage.
Install the roof opening panel.
2. Tighten the retaining bolts in the sequence
shown.

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501-17-17 Roof Opening Panel 501-17-17

REMOVAL AND INSTALLATION (Continued)

3. Attach the drain hoses to the roof opening

panel.

4. Install the headliner. For additional

information, refer to Section 501-05.

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501-17-18 Roof Opening Panel 501-17-18

REMOVAL AND INSTALLATION

Roof Opening Panel Glass

Removal
1. Move the roof opening panel shield rear- 4. Remove the roof opening panel glass.
wards.

2. NOTE: Make sure the roof opening panel is in Installation

the vent position.
Remove the roof opening panel guide arm 1. Position the roof opening panel glass in
covers. the roof opening panel.
2. NOTE: Do not fully tighten the retaining screws
at this stage.
Install the roof opening panel glass.

3. Remove the roof opening panel glass re-

taining screws on both sides.

3. Align the roof opening panel glass. For

additional information, refer to Roof
Opening Panel Alignment - in this section.

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501-17-19 Roof Opening Panel 501-17-19

REMOVAL AND INSTALLATION (Continued)

4. NOTE: Make sure the roof opening panel is in

the vent position.
Install the roof opening panel guide arm
covers.

5. Move the roof opening panel shield for-

wards.

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501-17-20 Roof Opening Panel 501-17-20

REMOVAL AND INSTALLATION

Roof Opening Panel Motor (33 786 0)

Removal
1. Remove the overhead console. For Installation
additional information, refer to Section
501-12. 1. Remove the roof opening panel guide arm
2. Disconnect the roof opening panel motor covers.
electrical connector (headliner shown re-
moved for clarity).

2. CAUTION: The guide pins must be

aligned centrally between the lugs as
3. Remove the roof opening panel motor. shown.
Check the alignment of the left-hand and
right-hand cable guide (left-hand side
shown).
• Depress the bar.

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501-17-21 Roof Opening Panel 501-17-21

REMOVAL AND INSTALLATION (Continued)

3. Adjust the left-hand cable guide pin. 7. Connect the battery ground cable. For
• Using a suitable screwdriver, move the ca- additional information, refer to Section
ble in the direction required. 414-01.
8. Connect the roof opening panel control
switch electrical connector.
9. CAUTION: This step must be carried
out if installing a previously used roof
opening panel motor.
NOTE: This step is not necessary when installing
a new roof opening panel motor.
Carry out the erasing roof opening panel
motor initialization procedure. For
additional information, refer to Roof
Opening Panel Motor Initialization in this
section.
10. Disconnect the battery ground cable. For
4. Adjust the right-hand cable guide pin. additional information, refer to Section
• Using a suitable screwdriver, move the ca- 414-01.
ble in the direction required. 11. Disconnect the roof opening panel
control switch electrical connector.
12. Install the roof opening panel motor.

5. Install the roof opening panel guide arm

covers.
13. Install the overhead console. For
additional information, refer to Section
501-12.
14. Carry out the initial roof opening panel
motor initialization procedure. For
additional information, refer to Roof
Opening Panel Motor Initialization in this
section.

6. NOTE: Support the roof opening panel motor.

Connect the roof opening panel motor
electrical connector.

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501-19-1 Bumpers 501-19-1

SECTION 501-19 Bumpers

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-19-2

REMOVAL AND INSTALLATION

Front Bumper Cover ..................................................................................... (43 427 0) 501-19-3

Rear Bumper Cover — 1.8L/2.0L/2.5L/2.0L Diesel ....................................... (43 447 0) 501-19-5

08/2002 2003.0 Mondeo

501-19-2 Bumpers 501-19-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Front bumper retaining bolts 15 11 –
Rear bumper bracket retaining bolts 15 11 –
Rear bumper bracket retaining nuts 15 11 –
Rear bumper to bumper bracket retaining nuts 20 15 –
Rear bumper to bumper bracket retaining bolts 20 15 –

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501-19-3 Bumpers 501-19-3

REMOVAL AND INSTALLATION

Front Bumper Cover (43 427 0)

REMOVAL AND INSTALLATION

Removal 4. Disconnect the low temperature warning

indicator electrical connector.
All vehicles
1. Remove the radiator grille.

5. Disconnect the fog lamp electrical connec-

tors (if equipped).
2. Remove the headlamp washer covers (if
equipped).

6. Detach the fender splash shield from the

bumper cover on both sides.
3. Remove the radiator undershield.

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501-19-4 Bumpers 501-19-4

REMOVAL AND INSTALLATION (Continued)

Vehicles with 1.8L, 2.0L, 2.5L or diesel engine Installation
7. Detach the bumper cover from the fender
on both sides. 1. To install, reverse the removal procedure.

Vehicles with 3.0L engine

8. Detach the bumper cover from the fender
on both sides.

All vehicles
9. Remove the bumper cover.

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501-19-5 Bumpers 501-19-5

REMOVAL AND INSTALLATION

Rear Bumper Cover — 1.8L/2.0L/2.5L/2.0L Diesel (43 447 0)

Removal 4. Detach the bumper cover from the fender

on both sides.
4-door
1. Remove the bumper cover retaining
screws.

Wagon
5. Detach the bumper cover from the spare
wheel housing.
All vehicles
2. Raise and support the vehicle. For
additional information, refer to Section
100-02.
3. Detach the fender splash shield from the
bumper cover on both sides.

4-door and 5-door

6. Detach the bumper cover from the spare
wheel housing.

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501-19-6 Bumpers 501-19-6

REMOVAL AND INSTALLATION (Continued)

All vehicles
7. Detach the parking aid sensors from the
bumper cover (if equipped).

8. Remove the bumper cover.

Installation
1. To install, reverse the removal procedure.

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501-20A-1 Safety Belt System 501-20A-1

SECTION 501-20A Safety Belt System

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-20-2

DESCRIPTION AND OPERATION

Safety Belt System ............................................................................................................ 501-20-3

DIAGNOSIS AND TESTING

Safety Belt System ............................................................................................................ 501-20-4

Principles of Operation ..................................................................................................... 501-20-4
Emergency Locking Retractor (ELR) ................................................................................ 501-20-4
Vehicle Motion Sensor (VMS)........................................................................................... 501-20-4
Webbing Motion Sensor (WMS) ....................................................................................... 501-20-4
Inspection and Verification ............................................................................................... 501-20-5
Symptom Chart ................................................................................................................ 501-20-5
Component Test............................................................................................................... 501-20-5
Static Test ........................................................................................................................ 501-20-6

REMOVAL AND INSTALLATION

Front Safety Belt Retractor ........................................................................... (40 222 0) 501-20-7

Rear Safety Belt Retractor — 4-Door/5-Door................................................ (40 248 0) 501-20-9
Rear Safety Belt Retractor — Wagon ........................................................... (40 248 0) 501-20-12
Safety Belt Buckle and Pretensioner............................................................. (40 232 0) 501-20-14
Rear Center Safety Belt Retractor — 5-Door/Wagon......................................................... 501-20-15
Rear Center Safety Belt Retractor — 4-Door ..................................................................... 501-20-16
Safety Belt Shoulder Height Adjuster............................................................ (40 225 0) 501-20-18

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501-20A-2 Safety Belt System 501-20A-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Safety belt retractor retaining bolts 38 28 –
Safety belt upper anchor retaining bolts 38 28 –
Safety belt lower anchor retaining bolts 38 28 –
Rear safety belt buckle retaining bolts 55 41 –
Safety belt shoulder height adjuster retaining bolts 25 18 –
Safety belt buckle and pretensioner retaining bolts 50 37 –

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501-20A-3 Safety Belt System 501-20A-3

DESCRIPTION AND OPERATION

Safety Belt System

DESCRIPTION AND OPERATION

the instrument cluster. For additional information,

WARNING: All safety belt components refer to Section 501-20A / 501-20B.
including retractors, buckles, child
safety seat tether brackets and attaching The safety belt buckle pretensioners have a
hardware in use during a collision must lower deployment threshold than that required by
be removed and new components the air bags. Hence it is possible during a minor
installed. New safety belt components collision, which exceeds the deployment
should also be installed where safety threshold, that only the safety belt prestensioners
belts not in use during a collision, are will deploy. However the safety belt buckle
inspected and found to be damaged or pretensioners will only deploy if the safety belt is
operate incorrectly. Failure to follow fastened.
these instructions may result in personal On vehicles equipped with a Generic Electronic
injury. Module, the safety belt system will warn the
driver that the safety belt is not fastened by
sounding a chime and then illuminating a warning
indicator located in the instrument cluster. For
additional information, refer to Diagnosis and
Testing in this section.
Vehicles built 10/2001 onwards, have an
additional safety belt minder. When the vehicle
speed exceeds 8 km/h (5 mph) and the driver
safety belt is unfastened, the safety belt minder
will provide the driver with an audible and visual
warning. The warning will continue for up to five
minutes by sounding a chime and illuminating a
warning indicator located in the instrument
WARNING: All vehicles fitted with a cluster.
passenger air bag have a WARNING The additional safety belt minder feature can be
sticker attached to the instrument panel disabled. For additional information, refer to
PROHIBITING the use of rear facing child Section 413-09.
seats in the front seating positions.
Failure to follow this instruction may Both front seats are equipped with active head
result in personal injury. restraints, which extend forward in the event of a
rear collision. For additional information, refer to
The safety belt system utilizes three - point lap Section 501-10.
and diagonal safety belts in all seat positions.
Rear seat safety belt retractors and buckles are
The front safety belt retractors incorporate a load of the conventional type.
limiting device, which allows progressive payout
of additional safety belt webbing when the force
exerted exceeds a predetermined limit.
The front safety belt upper anchors are
connected to safety belt shoulder height
adjusters mounted in the B-pillar.
The front seat safety belt buckles incorporate
pretensioners and safety belt buckle switches.
Both the safety belt buckle switch and the safety
belt buckle pretensioner are connected to the air
bag control module. The air bag control module
monitors both circuits and if a fault is detected will
illuminate the air bag warning indicator located in

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501-20A-4 Safety Belt System 501-20A-4

DIAGNOSIS AND TESTING

Safety Belt System

DIAGNOSIS AND TESTING

indicator will extinguish after 60 seconds or if the

driver safety belt is fastened.
Principles of Operation The safety belt retractor, mounted within the base
WARNING: All safety belt components of the B-pillar, incorporates a torsion bar load-
including retractors, buckles, front safety limiting device. The device consists of a retractor
belt buckle support assemblies (slider reel which is mounted onto a spindle (torsion bar)
bar), child safety seat tether brackets which, once the sensor has locked the retractor
and attaching hardware in use during a reel and a predetermined load is applied, twists
collision must be removed and new and pays out additional webbing into the system.
components installed. New safety belt The deceleration force required to initiate this
components should also be installed sequence is approximately the same as that
where safety belts not in use during a required to initiate air bag deployment. The
collision, are inspected and found to be torsion bar load-limiting device will only react if
damaged or operate incorrectly. Failure the safety belt is in use at the time of impact.
to follow these instructions may result in Rear seat safety belt retractors do not use this
personal injury. type of retractor; they are equipped with a
The occupant restraint system utilizes three-point conventional retractor.
lap and diagonal safety belts in all seat positions.
Front seats are equipped with safety belt buckle Emergency Locking Retractor (ELR)
pretensioners, which are controlled as part of the
supplemental restraint system (SRS). REFER to The retractors in all seat positions feature ELR.
Section 501-20A / 501-20B. The rear seat safety The ELR is part of the safety belt system that in
belt buckles are mounted directly to the floor pan normal operation allows free movement of the
underneath the rear seat cushion. The safety belt belted occupant. In an emergency the ELR will
buckle attached to the driver and front passenger lock, preventing webbing payout and hence
seat is fitted with a switch, which is connected to forward movement of the occupant. Locking may
the SRS warning indicator in the instrument be achieved by one of two mechanisms:
cluster by the wiring harness and the air bag
control module. When the ignition is turned to the
RUN position the SRS warning indicator will Vehicle Motion Sensor (VMS)
illuminate for 3 seconds. If the SRS, including the VMS is operated by sudden deceleration of the
safety belt electrical system, is operating vehicle or excessive tilt. Once operated the VMS
correctly the SRS warning indicator will be causes a locking pawl to be engaged, thus
extinguished. If a fault is detected the SRS locking the retractor, preventing webbing payout.
warning indicator will generate a lamp fault code When the vehicle is stationary, the VMS
(LFC). stabilizes, causing the pawl to disengage and
On vehicles equipped with a Generic Electronic unlock the retractor, allowing webbing payout.
Module (GEM), the safety belt system will warn
the driver that the safety belt is not fastened by
sounding a chime and illuminating the warning Webbing Motion Sensor (WMS)
indicator in the instrument cluster. If during at The ELR WMS is operated by rapid acceleration
least the first 6 seconds after the ignition is of the webbing. Once operated, it causes a
switched to the Run or Start position, the driver locking pawl to be engaged thus locking the
safety belt is not fastened, the safety belt warning retractor. Webbing payout is prevented in the
chime will sound. The chime will stop after 6 same manner as VMS.
seconds or if the driver safety belt is fastened. If
during the first 65 seconds after the ignition is
switched to the Run or Start position, the driver
safety belt is not fastened, the safety belt warning
indicator will be illuminated. The warning

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501-20A-5 Safety Belt System 501-20A-5

DIAGNOSIS AND TESTING (Continued)

Inspection and Verification Mechanical

1. Verify the customer concern. Safety belt retractor
Safety belt buckle and pretensioner
2. Visually inspect for obvious signs of
mechanical or electrical damage. 3. If an obvious cause for an observed or
3. reported concern is found, correct the cause
(if possible) before proceeding to the next
step.
Visual Inspection Chart
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart

Condition Possible Sources Action

• Normal mode - occupant re- • Safety belt retractor. • CARRY OUT the Safety Belt
straint system inoperative Component Test in this section.

Test Method 1 (braking)

Component Test
WARNING: It is important that during this
Poor Retraction test the driver and passenger allows the
safety belts to provide the restraint and
If a safety belt does not retract correctly, check do not attempt to anticipate the sudden
that the anchor covers and trim bezels are deceleration. The steering wheel should
correctly installed and not rubbing against the not be used as a brace. However, both
safety belt webbing. Where necessary, check driver and passenger should prepare
that the safety belt webbing is not rubbing at one themselves for the possibility that the
end of the retractor cover slot and, if so, correct safety belt will not lock. The passenger
by loosening the retaining bolt, aligning the should hold their hands in front of them,
retractor to centralize the safety belt webbing and just clear of the instrument panel or front
retighten the bolt. seat backrest, depending on which
These safety belts are ``dual sensitive" which safety belt is being tested. Failure to
means that they have: follow these instructions may result in
personal injury.
• a vehicle motion sensor, which locks the
safety belt webbing under braking, cornering,
on steep hills and in adverse camber
conditions.
• a webbing motion sensor, which locks when
the safety belt webbing is quickly extracted.
Both systems should be fully operational and can
be checked by the tests below:

Vehicle Motion Sensor Test

Either of the following two procedures may be
used to check correct operation of the vehicle
motion sensor. Both methods require two
technicians but note that technicians of larger
than normal build should not be asked to conduct
these tests. This is to avoid the possibility of a
fully unrolled safety belt webbing being mistaken
for a correctly locked safety belt retractor.

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501-20A-6 Safety Belt System 501-20A-6

DIAGNOSIS AND TESTING (Continued)

• Select for this test a quiet or private stretch of 0.25 meter (10 inches), preventing further
road. Make sure that the road is clear and webbing payout. Any safety belt retractor from
that full visibility is maintained at all times. which it is possible to extract further webbing
• Both driver and passenger should adopt a must not be used. A new safety belt must be
normal, comfortable seating position. Both installed.
occupants should wear the safety belts and
the safety belt webbing must be correctly
adjusted, with no slack.
• Proceed at a speed of 10 km/h (6 mph). Do
not exceed 10 km/h (6 mph) for this test.
• Apply the foot brake sharply to stop the
vehicle. If the vehicle motion sensitive lock
mechanism is operating correctly, the safety
belt webbing will lock and restrain the wearer.
• Conduct the test twice in each front and rear
passenger seat position.
• Any safety belt retractor which does not
restrain the wearer during this test must not
be reused. A new safety belt must be
installed.

Test Method 2 (turning circle)

This method requires a flat open area of private
road, sufficient for the vehicle to be driven in a
continuous circle on full steering lock.
• The driver should wear the safety belt
provided and the belt webbing must be
correctly adjusted, with no slack.
• The passenger should occupy a rear seat
with the safety belt correctly adjusted, with no
slack.
• Start the engine and, with the steering on full
right-hand lock, drive the vehicle in a
continuous circle at 16 km/h (10mph). Do not
exceed 16 km/h (10 mph) for this test.
• When the speed is stable, the passenger
should attempt to slowly extract the safety
belt webbing from each safety belt retractor in
turn. If the vehicle motion sensitive lock
mechanism is operating correctly, it will not
be possible to extract the webbing.
• Any safety belt retractor from which it is
possible to extract the webbing during this
test must not be used. A new safety belt must
be installed.

Static Test
With the vehicle stationary and on level ground
take firm hold of the safety belt webbing (on the
tongue side of the safety belt upper anchor) and
pull out quickly. The retractor should lock within

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501-20A-7 Safety Belt System 501-20A-7

REMOVAL AND INSTALLATION

Front Safety Belt Retractor (40 222 0)

REMOVAL AND INSTALLATION

Removal 5. Remove the B-pillar upper trim panel.

1. Detach the locating tangs from the B-pillar
1. Move the seat fully forwards.
lower trim panel.
2. Detach the safety belt lower anchor from
2. Remove the screw cover.
the underside of the seat.
3. Remove the screw.
• Feed the safety belt webbing through the
B-pillar upper trim panel.

3. Detach the door opening weatherstrips

from the B-pillar.

6. Remove the B-pillar lower trim panel and

reinforcement plate.
1. Remove the screws.
2. Release the clips.

4. Move the safety belt shoulder height

adjuster to its lowest position.

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501-20A-8 Safety Belt System 501-20A-8

REMOVAL AND INSTALLATION (Continued)

7. Remove the cowl side trim panel (front 9. Detach the guide loop from the B-pillar.
seat shown removed for clarity).
1. Remove the screws.
2. Release the clips.

10. Remove the front safety belt retractor.

1. Remove the bolt.
2. Lift the retractor to detach the locating
8. CAUTION: The bolt securing the safety tang.
belt anchor is held captive by a paper
washer. The bolt, spacer and paper
washer must remain on the safety belt
anchor at all times when the safety
belt is detached or removed.
Detach the safety belt upper anchor from
the safety belt shoulder height adjuster.

Installation
1. CAUTION: Make sure the safety belt
retractor locating tang is correctly
located.
NOTE: Make sure the safety belt shoulder height
adjuster locking control is correctly located on the
safety belt shoulder height adjuster.
To install, reverse the removal procedure.

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501-20A-9 Safety Belt System 501-20A-9

REMOVAL AND INSTALLATION

Rear Safety Belt Retractor — 4-Door/5-Door (40 248 0)

Removal 3. Remove the C-pillar lower trim panel

(vehicles with trim panel shown vehicles
All vehicles
with seat bolster similar).
1. Detach the rear door opening weatherstrip
from the C-pillar. • Remove the C-pillar lower trim panel re-
taining screw.

2. Detach the rear safety belt lower anchor

from the floor panel. 4-door
4. Remove the C-pillar trim panel.
• Feed the safety belt webbing through the
C-pillar trim panel.

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501-20A-10 Safety Belt System 501-20A-10

REMOVAL AND INSTALLATION (Continued)

5-door 7. Remove the C-pillar center trim panel.
5. Remove the C-pillar upper trim panel 1. Remove the retaining screws.
screw.
2. Detach the retaining clip.
• Remove the C-pillar trim panel blanking
• Feed the safety belt webbing through the
plug and retaining screw.
C-pillar center trim panel.

6. Remove the C-pillar upper trim panel.

All vehicles
• Detach the C-pillar trim panel retaining
clips and disconnect the rear window 8. CAUTION: The bolt securing the safety
washer tube from the right-hand C-pillar belt anchor is held captive by a paper
trim panel. washer. The bolt, spacer and paper
washer must remain on the safety belt
anchor at all times when the safety
belt is detached or removed.
Detach the safety belt upper anchor from
the C-pillar.

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501-20A-11 Safety Belt System 501-20A-11

REMOVAL AND INSTALLATION (Continued)

9. Remove the rear safety belt retractor.

1. Remove the retaining bolt.
2. Lift the retractor to detach the locating
tangs.

Installation
1. CAUTION: Make sure the safety belt
retractor locating tangs are correctly
located.
To install, reverse the removal procedure.

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501-20A-12 Safety Belt System 501-20A-12

REMOVAL AND INSTALLATION

Rear Safety Belt Retractor — Wagon (40 248 0)

Removal
1. Detach the liftgate opening weatherstrip 4. Remove the load space upper trim panel.
from the D-pillar. • Remove the load space upper trim panel
retaining screws.

2. Remove the D-pillar trim panel.

• Detach the D-pillar trim panel and discon- 5. Detach the rear safety belt lower anchor
nect the rear washer tube from the right- from the floor panel.
hand D-pillar trim panel.

3. Detach the rear door opening weatherstrip

from the C-pillar.

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501-20A-13 Safety Belt System 501-20A-13

REMOVAL AND INSTALLATION (Continued)

Installation
6. CAUTION: The bolt securing the safety 1. CAUTION: Make sure the safety belt
belt anchor is held captive by a paper retractor locating tangs are correctly
washer. The bolt, spacer and paper located.
washer must remain on the safety belt
anchor at all times when the safety To install, reverse the removal procedure.
belt is detached or removed.
Detach the safety belt upper anchor from
the C-pillar.
1. Detach the bolt cover.
2. Remove the retaining bolt.

7. NOTE: Reposition the load space trim panel

carpet to access the rear safety belt retractor.
Remove the rear safety belt retractor.
1. Remove the retaining bolt.
2. Lift the retractor to detach the locating
tangs.

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501-20A-14 Safety Belt System 501-20A-14

REMOVAL AND INSTALLATION

Safety Belt Buckle and Pretensioner (40 232 0)

Removal 4. Remove the safety belt buckle and preten-

sioner.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
1. Remove the front seat. For additional
information, refer to Section 501-10.
2. Disconnect the safety belt buckle switch
and the safety belt buckle pretensioner
electrical connectors.

Installation
1. WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal
injury.
3. CAUTION: Note the position and To install, reverse the removal procedure.
routing of the safety belt buckle
switch and the safety belt buckle
pretensioner wiring harnesses to aid
assembly. An incorrectly routed
wiring harness may lead to the wiring
harness becoming damaged on the
seat mechanism.
Detach the safety belt buckle switch and
the safety belt buckle pretensioner wiring
harnesses from the underside of the seat.

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501-20A-15 Safety Belt System 501-20A-15

REMOVAL AND INSTALLATION

Rear Center Safety Belt Retractor — 5-Door/Wagon

4. Using a suitable knife, cut the rear seat
backrest carpet to access the safety belt
retractor retaining bolt.
General Equipment
Knife

Removal
1. Disassemble the rear seat backrest. For
additional information, refer to Section
501-10.
2. Lock the rear seat backrest latch.

5. Remove the rear center safety belt

retractor.
• Feed the safety belt webbing and safety
belt buckle through the guide loop.

3. NOTE: Note the backrest latch cable position

on the safety belt retractor to aid installation.
Detach the backrest latch cable from the
safety belt retractor.

Installation
1. CAUTION: Check the backrest latch
cable routing, and the operation of the
safety belt retractor and interlock
before fully assembling the rear seat
backrest.
NOTE: Reinstall the self-adhesive backrest
carpet to give the necessary finish.
To install, reverse the removal procedure.

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501-20A-16 Safety Belt System 501-20A-16

REMOVAL AND INSTALLATION

Rear Center Safety Belt Retractor — 4-Door

Removal 4. Detach the center safety belt and buckle

lower anchor from the floor panel.
1. Detach the rear door opening weatherstrip
from the C-pillars.

5. Fold down the rear seat backrests.

6. Remove the center safety belt webbing
2. Remove the C-pillar lower trim panels
trim panel.
(vehicles with trim panel shown vehicles
with seat bolster similar).
• Remove the C-pillar lower trim panel re-
taining screw.

7. Remove the rear seat backrest retaining

latch trim panels.

3. Remove the rear seat cushion.

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501-20A-17 Safety Belt System 501-20A-17

REMOVAL AND INSTALLATION (Continued)

8. Remove the parcel shelf.

• Feed the safety belt webbing through the
parcel shelf.

9. Remove the rear center safety belt retrac-

tor.

Installation
1. To install, reverse the removal procedure.

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501-20A-18 Safety Belt System 501-20A-18

REMOVAL AND INSTALLATION

Safety Belt Shoulder Height Adjuster (40 225 0)

Removal
4. CAUTION: The bolt securing the safety
1. Detach the front and rear door opening belt anchor is held captive by a paper
weatherstrips from the B-pillar. washer. The bolt, spacer and paper
washer must remain on the safety belt
anchor at all times when the safety
belt is detached or removed.
Detach the safety belt upper anchor from
the safety belt shoulder height adjuster.

2. Move the safety belt shoulder height

adjuster to its lowest position.
3. Detach the B-pillar upper trim panel from
the B-pillar and position it to one side.
1. Detach the locating tangs from the B-pillar
lower trim panel. 5. Remove the safety belt shoulder height
adjuster.
2. Remove the screw cover.
1. Remove the bolt.
3. Remove the screw.
2. Lift the adjuster to detach the locating tang.

Installation
1. NOTE: Make sure the safety belt shoulder
height adjuster locking control is correctly
located on the safety belt shoulder height
adjuster.
To install, reverse the removal procedure.

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501-20B-1 Supplemental Restraint System 501-20B-1

SECTION 501-20B Supplemental Restraint System

VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 501-20-3

DESCRIPTION AND OPERATION

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS).................... 501-20-4
Air Bag Control Module .................................................................................................... 501-20-6
Front Two Stage Air Bag Modules. ................................................................................... 501-20-6
Side Air Bag Modules ....................................................................................................... 501-20-7
Side Air Curtain Modules.................................................................................................. 501-20-8
Front Safety Belt Buckle and Pretensioners ..................................................................... 501-20-9
Air Bag and Safety Belt Pretensioners Deployment Logic ................................................ 501-20-9
Clockspring ...................................................................................................................... 501-20-10
Crash Sensor ................................................................................................................... 501-20-10
Side Impact Sensor .......................................................................................................... 501-20-10
Occupant Classification Sensor........................................................................................ 501-20-10
Seat Position Sensor ........................................................................................................ 501-20-11
Air Bag Warning Indicator................................................................................................. 501-20-11
Passenger Air Bag Deactivation (PAD) Indicator .............................................................. 501-20-12

DIAGNOSIS AND TESTING

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS).................... 501-20-13
Diagnosing Customer Concerns Without Hard DTCs/LFCs .............................................. 501-20-13
Diagnosing Customer Concerns with Hard DTCs/LFCs.................................................... 501-20-13
Deactivation ..................................................................................................................... 501-20-13
Reactivation ..................................................................................................................... 501-20-14
Glossary........................................................................................................................... 501-20-15
Principles of Operation ..................................................................................................... 501-20-15
Inspection and Verification ............................................................................................... 501-20-16
Diagnostic Instructions - Air Bag and Safety Belt Pretensioner Supplemental Restraint
System (SRS) .................................................................................................................. 501-20-17
Inspection and Verification ............................................................................................... 501-20-17
Symptom Chart ................................................................................................................ 501-20-17
Pinpoint Tests - Air Bag and Safety Belt Pretensioner Supplemental Restraint System
(SRS) ............................................................................................................................... 501-20-24
Pinpoint Tests .................................................................................................................. 501-20-24

GENERAL PROCEDURES

Deployed Air Bag Disposal ................................................................................................ 501-20-144

Unserviceable Air Bag Disposal......................................................................................... 501-20-145
Scrapped Vehicle Undeployed Air Bag Disposal ............................................................... 501-20-146
Safety Belt Pretensioner Disposal ..................................................................................... 501-20-149

REMOVAL AND INSTALLATION

Side Impact Sensor ...................................................................................... (40 699 0) 501-20-151

Crash Sensor .................................................................................................................... 501-20-153

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501-20B-2 Supplemental Restraint System 501-20B-2

Air Bag Control Module ................................................................................. (33 650 0) 501-20-154

Driver Air Bag Module ................................................................................... (40 700 0) 501-20-155
Passenger Air Bag Module............................................................................ (40 701 0) 501-20-158
Side Air Bag Module ..................................................................................... (40 698 0) 501-20-161
Side Air Curtain Module — 4-Door ..................................................................................... 501-20-163
Side Air Curtain Module — 5-Door ..................................................................................... 501-20-168
Side Air Curtain Module — Wagon..................................................................................... 501-20-173
Clockspring ........................................................................................................................ 501-20-178
Occupant Classification Sensor.......................................................................................... 501-20-183

08/2002 2003.0 Mondeo

501-20B-3 Supplemental Restraint System 501-20B-3

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Driver air bag module retaining screws 5 – 44
Passenger air bag module to cross-vehicle beam 10 – 89
retaining bolts
Passenger air bag module to instrument panel re- 7 – 62
taining bolts
Passenger air bag module deployment guide re- 4 – 35
taining nuts
Side air bag module retaining screws 3 – 27
Side air curtain module retaining bolts 5 – 44
Air bag control module retaining nuts 7 – 62
Crash sensor retaining bolt 8 – 71
Side impact sensor retaining bolt 7 - 62

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501-20B-4 Supplemental Restraint System 501-20B-4

DESCRIPTION AND OPERATION

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
DESCRIPTION AND OPERATION

impact. Optimum protection can only be achieved

The supplemental restraint system (SRS) has
when used in conjunction with the conventional
been specifically designed to protect the driver
three-point safety belts. The safety belts form an
and passengers from sustaining severe facial
integral part of the SRS.
and upper body injuries in the event of a serious

Item Part Description

Number
1 Passenger air bag module

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501-20B-5 Supplemental Restraint System 501-20B-5

DESCRIPTION AND OPERATION (Continued)

Item Part Description Vehicles equipped with side air bags can be
Number identified by an embossed AIRBAG logo on the
seat fabric adjacent to the air bag module. A label
2 Occupant classification sen- is attached to the B-pillar adjacent to the seat.
sor
3 Driver air bag module
4 Air bag control module
5 Side air curtain module
6 Side impact sensor
7 Seat position sensor
8 Safety belt buckle switch
'part of the safety belt buckle
and pretensioner'
9 Crash sensor

The driver, wearing the safety belt provided,

should position the seat as far back as is
practical, so the steering wheel can be reached
with arms slightly angled, thereby leaving a gap
between the steering wheel and the driver.
The passenger, wearing the safety belt provided,
should not position himself or herself so that the
air bag cover is in direct contact with the
occupants' body.
The front air bags and safety belt buckle
pretensioners will deploy in the event of a direct
front impact or when the impact angle is up to 30
degrees from the left or right of the vehicle center
line.
The air bag(s) and safety belt buckle
pretensioners will deploy only once. In a collision
in which they deployed at the first impact, the air
bag(s) and safety belt pretensioners will not
reduce the risk of injury in a subsequent impact.
In the event of a side impact, in which the side air
bags deploy, the front air bags will still deploy in a
subsequent front impact, provided that the front
impact exceeds the triggering threshold.
Under certain circumstances, although the
damage sustained by the vehicle may look
extensive, the impact may remain below the
triggering threshold of the SRS and the air bags WARNING: All vehicles fitted with the
will not deploy. In such circumstances the safety passenger air bag from the factory have
belts would provide sufficient protection for the a WARNING sticker attached to the
occupants. instrument panel, PROHIBITING the use
of rear facing child or baby seats.
The visible VIN plate, which shows the air bag
symbol and either X1, X2 or X4 dependent on the The SRS consists of the following components:
number of air bags fitted, is attached to the
windshield edge of the instrument panel.

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501-20B-6 Supplemental Restraint System 501-20B-6

DESCRIPTION AND OPERATION (Continued)

• Air bag control module with integral crash sufficient to deploy the air bag(s) for a minimum
sensor of 150 mS. The vehicle battery supply maintains
• Front two stage air bag modules the air bag control module auxiliary supply and
supports all other SRS functions when the
• Side air bag modules
ignition is in the 'RUN' position. In the event of a
• Side air curtain modules fault being detected by the air bag control module
• Front safety belt buckle and pretensioners the air bag warning indicator is illuminated. The
(includes a safety belt buckle switch) behavior of the warning indicator depends on the
• Clockspring type of fault present.
• Crash sensor The air bag control module can be reset, using
• Side impact sensors (vehicle equipped with WDS, and used for up to five collisions in which
side air bags) the air bags deployed.
• Passenger occupant classification sensor
• Driver seat position sensor
Front Two Stage Air Bag Modules.
• Air bag warning indicator
• Passenger air bag deactivation indicator

Air Bag Control Module

The air bag control module, located under the
floor console, governs the operation of the whole
system and performs continual system
diagnostics. Information on the severity of an
impact is received from the crash sensor and, in
the event of a side impact, the corresponding
side impact sensor.
In the event of a frontal impact, in excess of a
predetermined limit, the air bag control module
will evaluate the signal received from the front
crash sensor against stored data and deploy the
front air bag modules and the safety belt buckle Item Part Description
pretensioners. However, the safety belt buckles Number
will only deploy if the safety belt buckle is 1 Driver air bag module first
fastened. Variations in the deployment of the stage electrical connection
front air bag modules are dependent on the (black electrical connector)
status of the driver seat position, passenger
occupant classification sensor and the front 2 Driver air bag module sec-
safety belt buckles. ond stage electrical connec-
tion (brown electrical con-
In the event of a side impact, in excess of a nector)
predetermined limit, the air bag control module
will evaluate the signal received from either of the
side impact sensors against stored data and
deploy the corresponding side air bag module
and, if equipped, the side air curtain module.
On vehicles equipped with the telematics system
there is an interface with the telematics control
module. In the event of an air bag deployment
the telematics control module will automatically
send a SOS signal.
In the event of a failure in the vehicle power
supply during an accident, the air bag control
module provides an auxiliary power supply,

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501-20B-7 Supplemental Restraint System 501-20B-7

DESCRIPTION AND OPERATION (Continued)

the instrument panel which has invisible 'split

lines' to allow the passenger air bag to easily exit
when the system deploys. The passenger air bag
has a volume of 110 liters.
A new passenger air bag module and wiring
harness with the air bag module electrical
connectors must be installed following
deployment.
Both the driver and passenger air bag modules
contain two inflators. In the event of a frontal
impact, in excess of a predetermined limit, the air
bag control module will deploy the driver first
stage inflator followed by the second stage
inflator. The lapse time between the deployment
of the first stage inflator and the second stage
inflator is directly related to the accident severity
and the information received by the air bag
control module from the driver seat position
sensor.
The air bag control module will also deploy the
passenger air bag first stage inflator, provided
that the passenger occupant classification sensor
senses that the seat is occupied. The passenger
second stage inflator will then also deploy and
the lapse time between the first stage inflator
deployment and the second stage inflator
deployment is directly related to accident
severity.
Item Part Description
Number Regardless of the driver seat position or the
passenger occupant classification sensor (unless
1 Passenger air bag module the occupant classification sensor determines
first stage electrical connec- that the passenger seat is unoccupied) both the
tion (black electrical connec- second stage inflators will deploy 100 mS
tor) following the first stage deployment. This
2 Passenger air bag module 'disposal' deployment has no effect on the air bag
second stage electrical con- pressure, but is a protection measure for the
nector (brown electrical con- rescue services.
nector)
The driver air bag module is fitted to the steering Side Air Bag Modules
wheel, the cover forming the outer surface of the
The side air bag will deploy on the same side that
steering wheel boss. The cover has invisible 'split
the air bag control module received the signal
lines' molded in its surface allowing the air bag to
from the side impact sensor. The side air bag
easily exit through the cover when the system
modules, if equipped, are integrated into the front
deploys. The driver air bag has a volume of 55
seat backrests providing an unobtrusive
liters.
appearance. The unique seat cover has been
A new driver air bag module and wiring harness designed to accommodate air bag deployment.
with the air bag module electrical connectors When the side air bag is deployed the stitched
must be installed following deployment. seam of the seat cover adjacent to the side air
The passenger air bag module is located above bag module splits, allowing the air bag to exit the
the glove compartment and is secured to the seat backrest unobstructed. Each side air bag
cross-vehicle beam and the instrument panel. has a volume of 11 liters.
The passenger air bag cover is an integral part of

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501-20B-8 Supplemental Restraint System 501-20B-8

DESCRIPTION AND OPERATION (Continued)

Side Air Curtain Modules

deployed at the same time as the corresponding

Item Part Description side air bag. If the passenger air bag is
Number deactivated the corresponding side air bag is also
deactivated, however the side air curtain will still
1 Folded side air curtain mod- deploy to afford protection to any corresponding
ule rear occupant. When deployed, the side air
2 Side air curtain module elec- curtain extends down to approximately shoulder
trical connection height to protect both the front and rear
occupants heads. Both the front and rear of the
3 Roof panel side air curtain are retained to the A and C-pillar
4 Side air curtain module re- respectively by cords.
taining bolt The side air curtain inflator generates the gas
5 Side air curtain module infla- needed to fill the side air curtain. It consists of a
tor high strength steel casing filled with a solid
propellant charge, an electrically activated ignitor
6 Folded side air curtain and a cold gas bottle with pressurized gas. The
7 Side air curtain rear retaining ignitor is activated by a signal from the air bag
cord control module, which ignites the propellant. The
burning propellant opens the membrane of the
8 Unfolded side air curtain cold gas bottle and heats the pressurized gas.
The expanding gas is directed by the seal into
9 Side air curtain front retain-
the gas tube and emits through holes in the tube
ing cord
to the front and rear side air curtain chambers.
The side air curtain modules are located under The force of the occupant's heads on the side air
the headliner between the A and C-pillar and curtain forces the gas from the front and rear

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501-20B-9 Supplemental Restraint System 501-20B-9

DESCRIPTION AND OPERATION (Continued)

chambers into an overflow chamber, thus pretensioners provided the safety belt buckles
producing a dampening effect. Each side air are fastened. The safety belt buckle
curtain has an approximate volume of 24 liters. pretensioners have a lower deployment threshold
than that required by the air bags. Hence it is
A new side air curtain module and wiring harness
possible during a minor collision, which exceeds
with the air curtain module electrical connectors
the deployment threshold, that only the safety
must be installed following deployment.
belt pretensioners will deploy. The air bag control
module receives information on the status of the
safety belt buckles from a switch contained in the
Front Safety Belt Buckle and Pretensioners
buckle. For additional information, refer to
The front safety belt buckles and pretensioners Section 501-20A / 501-20B.
are seat mounted and incorporate a safety belt
A new safety belt buckle and pretensioner must
buckle switch. In the event of a front or side
be installed following deployment.
impact the air bag control module will deploy the
Air Bag and Safety Belt Pretensioners Deployment Logic
Restraint Device Deployment Criterion Deactivation Criterion
Exceed the pretensioner deploy- Driver safety belt buckle unfas-
Driver safety belt pretensioner
ment threshold tened
Exceed the driver or front passen-
ger side air bag deployment thresh-
old
Driver air bag Exceed the driver air bag deploy- -
ment threshold
Driver side air bag Exceed the driver side air bag de- -
ployment threshold
Driver side air curtain Exceed the driver side air bag de- -
ployment threshold
Front passenger safety belt Exceed the pretensioner deploy- Passenger safety belt buckle un-
pretensioner ment threshold fastened
Exceed the driver or front passen- Passenger seat not occupied
ger side air bag deployment thresh-
old
Front passenger air bag Exceed the front passenger air bag Passenger seat not occupied
deployment threshold
Front passenger side air bag Exceed the front passenger side air Passenger seat not occupied
bag deployment threshold
Passenger side air curtain Exceed the front passenger side air -
bag deployment threshold
threshold will be lower than a fastened safety belt
The driver and front passenger air bags have
buckle deployment threshold.
different deployment thresholds for when the
safety belt buckle is fastened or unfastened. If With the driver seat in the forward position and
the driver or front passenger safety belt buckle is the driver safety belt buckle fastened, the driver
unfastened the respective air bag deployment air bag will be deployed at the driver safety belt
buckle unfastened threshold.
Safety Belt Buckle Air Bag Deployment Threshold
Driver safety belt buckle fastened Driver air bag will be deployed at the fastened
threshold
Driver safety belt buckle unfastened Driver air bag will be deployed at the unfastened
threshold
Driver safety belt buckle fastened and the driver Driver air bag will be deployed at the unfastened
seat in the forward position threshold

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501-20B-10 Supplemental Restraint System 501-20B-10

DESCRIPTION AND OPERATION (Continued)

Safety Belt Buckle Air Bag Deployment Threshold
Driver safety belt buckle unfastened and the driver Driver air bag will be deployed at the unfastened
seat in the forward position threshold
Front passenger safety belt buckle fastened Front passenger air bag will be deployed at the
fastened threshold
Front passenger safety belt buckle unfastened Front passenger air bag will be deployed at the un-
fastened threshold
side impact sensor against stored data. The air
Depending on which front safety belt buckle(s)
bag control module will deploy the side air bag,
are fastened and the severity of the impact, there
both safety belt buckle pretensioners and, if
are scenarios where it is possible that only one of
equipped, the side air curtain on the side the
the two front air bags will be deployed. For
deployment request was initiated.
example: The driver safety belt buckle
unfastened, passenger safety belt buckle The side impact sensors can be reused following
fastened and the impact has reached the external examination and system self-test.
unfastened threshold. The driver air bag will
deploy but the driver safety belt pretensioner will
not deploy, passenger air bag will not deploy but Occupant Classification Sensor
the passenger safety belt pretensioner will
NOTE: The occupant classification sensor is an
deploy.
integral part of the passenger seat cushion and
cannot be serviced separately.
Clockspring
The clockspring is designed to carry signals
between the air bag control module and the
driver air bag module. The clockspring is fitted to
the steering column, and consists of fixed and
moving parts connected by a coiled Mylar tape
with integral conducting tracks. The Mylar tape is
able to 'wind up' and 'unwind' as the steering
wheel (to which the moving part is attached) is
turned, maintaining electrical contact at all times
between the air bag control module and the
driver air bag module.
It is advisable to install a new clockspring
following a driver air bag deployment.

Crash Sensor
The front crash sensor is located under the
radiator grill opening panel to facilitate impact
sensing along the longitudinal axis. The air bag
control module processes the crash data sent by
the front crash sensor against stored data, and
deploys the front air bags.
The crash sensor can be reused following
external examination and system self-test.

Side Impact Sensor

The side impact sensors are mounted at the base
of the B-pillars to facilitate lateral impact sensing.
In the event of a side impact, the air bag control
module processes the crash data sent by the
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501-20B-11 Supplemental Restraint System 501-20B-11

DESCRIPTION AND OPERATION (Continued)

Item Part Description Seat Position Sensor

Number
1 Occupant classification sen-
sor mat
2 Seat sensors 'part of the oc-
cupant classification sensor
mat'

The passenger occupant classification sensor

consists of the following components:
• Sensor mat with integrated pressure sensors.
• Electronic control unit
• Wiring harness
The occupant classification sensor detects, by
integrated pressure sensors, the presence of a The seat position sensor is located on the driver
passenger or object on the seat cushion. The seat track. The seat position sensor determines
occupant classification sensor cannot the position of the driver seat, which is then
discriminate between a passenger and an object. communicated to the air bag control module. If
The electronic control unit processes the the driver seat is in the forward position, the
pressure information and, if the pressure exceeds driver air bag second stage is disabled.
a threshold, an 'Occupied Seat' state is
communicated through the wiring harness to the
air bag control module. If the seat is empty or Air Bag Warning Indicator
occupied by a very light object an 'Empty Seat'
state is transmitted to the air bag control module
and the passenger air bag will be deactivated to
avoid unnecessary repair costs. If the seat is
empty and the safety belt is buckled the
passenger air bag deactivation indicator will be
illuminated.
The occupant classification sensor system is not
affected by the position of the passenger seat.
The electronic control unit monitors the occupant
classification sensor and if a fault is detected will
communicate the fault to the air bag control
module through the corporate area network
(CAN) and illuminate the air bag warning light.
The air bag warning indicator is located in the
instrument cluster. In the event of a fault being
detected by the air bag control module, the
warning indicator flashes a corresponding flash
code five times and then remains illuminated.

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501-20B-12 Supplemental Restraint System 501-20B-12

DESCRIPTION AND OPERATION (Continued)

Passenger Air Bag Deactivation (PAD)
Indicator

The PAD indicator is located in the instrument

panel. The PAD indicator functions as follows:
• The PAD indicator performs a six second
prove out when the ignition is in the RUN
position, which is the same prove out time as
the air bag warning indicator.
• During the ignition cycle, the PAD indicator
will only illuminate if the passenger seat is
empty and the front passenger safety belt
buckle is fastened.

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501-20B-13 Supplemental Restraint System 501-20B-13

DIAGNOSIS AND TESTING

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
DIAGNOSIS AND TESTING

Refer to Wiring Diagrams Section 501-20B for NOTE: Following the pinpoint tests when a
schematic and connector information. diagnostic trouble code/lamp fault code
(DTC/LFC) is not present, will result in needless
Special Tool(s) replacement of air bag system components and
Simulator, Air Bag Module repeat repairs.
501–073 (40–016) Speak with the customer to determine if a
particular set of conditions must be met in order
for a fault to occur. If a LFC is reported by the
customer but is not present when the vehicle
comes in for repair, pinpoint test diagnostics
Simulator, Occupant cannot be used. Instruct the customer on how to
Restraint Systems count a LFC.
501–077 (40–019)

Diagnosing Customer Concerns with Hard

DTCs/LFCs
Test and Deployment Lead,
Driver; Passenger and Side WARNING: Do not use substitute air bag
Air Bag Module simulators when working on the
418–525 (40–007–14) supplemental restraint system. Use only
the appropriate tool. Failure to follow this
instruction may result in personal injury.
Test and Deployment Lead, Most air bag system diagnostic procedures
Side Air Curtain Module require the use of system deactivation and
418–141 (40–007–08) system reactivation procedures. These
procedures require the air bag module(s) and
safety belt buckle pretensioners to be
disconnected from the SRS, thereby removing
Test and Deployment Lead, the risk of air bag deployment while diagnostics
Air Bag/Pyrotechnic Safety are carried out.
Belt
Air bag simulators are required to carry out
418–S055 (40–007A) diagnosis and testing of the air bag system. The
simulator contains a resistor, used to simulate an
air bag module connection to the system. It is not
General Equipment acceptable to short-circuit the air bag module
connections with a 0 ohm jumper wire. If a 0 ohm
WDS jumper wire is used to short-circuit the air bag
module connections, a LFC will be displayed and
a DTC logged by the air bag control module.
Diagnosing Customer Concerns Without Hard
DTCs/LFCs
Deactivation
WARNING: The back up power supply
must be depleted, before any work is WARNING: The back up power supply
carried out on the supplemental restraint must be depleted, before any work is
system. Wait at least one minute after carried out on the supplemental restraint
disconnecting the battery ground cable. system. Wait at least one minute after
Failure to follow this instruction may disconnecting the battery ground cable.
result in personal injury. Failure to follow this instruction may
result in personal injury.

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501-20B-14 Supplemental Restraint System 501-20B-14

DIAGNOSIS AND TESTING (Continued)

NOTE: When the passenger underseat simulator 3. Remove the driver air bag module from the
is installed on vehicles equipped with the vehicle. REFER to Driver Air Bag Module in
Occupant Classification System, the passenger this section.
air bag deactivation (PAD) indicator will illuminate 4. Connect the air bag simulators to the sub-
continuously when the ignition is turned to the harnesses in place of the driver air bag
RUN position, provided the seat is empty. The module at the top of the steering column.
simulator is designed to simulate an empty seat 5. Disconnect the passenger air bag module
and a fastened passenger safety belt buckle.
electrical connectors. REFER to Passenger
1. Disconnect the battery ground cable. REFER Air Bag Module in this section.
to Section 414-01.
6. Connect the air bag simulators to the wiring
2. Wait at least one minute for the backup harnesses in place of the passenger air bag
power supply in the air bag control module to module.
deplete its stored energy.
7. Disconnect the both side air curtain module
WARNING: Place the air bag module on a electrical connectors. REFER to Side Air
ground wired bench, with the trim cover Curtain Module-4-Door / Side Air Curtain
facing up to avoid accidental Module-5-Door / Side Air Curtain Module-
deployment. Failure to follow this Wagon in this section.
instruction may result in personal injury. 8. Connect the air bag simulators to the wiring
harnesses in place of the side air curtain
modules.
9. Disconnect the driver underseat air bag
electrical connector.
10. Connect the driver underseat air bag
simulator to the floor harness.
11. Disconnect the passenger underseat air
bag electrical connector.
12. Connect the passenger underseat air bag
simulator between the floor harness electrical
connector and the passenger seat harness
electrical connector.
13. Connect the battery ground cable.
REFER to Section 414-01.

Reactivation
WARNING: The air bag simulators must
be removed and the air bag modules
reconnected when reactivated to avoid
non-deployment in a collision. Failure to
follow this instruction may result in
personal injury.

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501-20B-15 Supplemental Restraint System 501-20B-15

DIAGNOSIS AND TESTING (Continued)

1. Disconnect the battery ground cable. REFER flashes a corresponding fault code five times and
to Section 414-01. then remains illuminated continuously.
2. Wait at least one minute for the backup
power supply in the air bag control module to Reactivate the System
deplete its stored energy.
3. Remove the driver air bag simulators from Reactivate the system means to carry out the
the sub-harness at the top of the steering reactivation procedure.
column.
4. Connect and install the driver air bag module.
Principles of Operation
REFER to Driver Air Bag Module in this
section.
5. Remove the passenger air bag simulators Supplemental Restraint System (SRS) Operation
from the passenger air bag module wiring The vehicle is equipped with a DC fired sensing
harnesses. system.
6. Connect and install the passenger air bag
Air bag deployment will only occur, in the event of
module. REFER to Passenger Air Bag
a severe collision when the ignition key is in the
Module in this section.
RUN position.
7. Remove the side air curtain simulators from
the side air curtain module wiring harnesses.
8. Connect and install the side air curtain Air Bag Control Module
modules. REFER to Side Air Curtain The air bag control module retains full control of
Module-4-Door / Side Air Curtain Module-5- the whole system, providing continual system
Door / Side Air Curtain Module-Wagon in checks and full diagnostic capabilities. The non-
this section. volatile memory stores the fault codes, which are
9. Remove the driver underseat air bag down loaded through the diagnostic link
simulator. connector to WDS.
10. Connect the driver underseat air bag In the event of a failure in the vehicle power
electrical connector. supply during an accident, the air bag control
11. Remove the passenger underseat air bag module provides an auxiliary power supply,
simulator. sufficient to deploy the front air bag(s) for a
12. Connect the passenger underseat air bag minimum of 150mS. The auxiliary power supply
electrical connector. is discharged by the air bag control within 60
seconds of the battery ground cable being
13. Connect the battery ground cable.
disconnected. Thus making sure the
REFER to Section 414-01.
supplemental restraint system remains
14. Prove out the system. operational.
The air bag control module contains a
Glossary microcontroller to evaluate and process impact
data. The front crash sensor discriminates frontal
impacts and provides information on the severity
Air Bag Simulator of the impact to the air bag control module. The
side impact sensors discriminates lateral impacts
Air bag simulators are used to simulate air bag
and provides information on the severity of the
module connections to the system.
impact to the air bag control module.
The air bag control module will initiate the
Deactivate the System deployment of the appropriate air bags as soon
Deactivate the system means to carry out the as an impact of sufficient severity is detected.
deactivation procedure.

Prove Out the System

The air bag warning indicator will illuminate for
six seconds. If a fault is detected the indicator
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501-20B-16 Supplemental Restraint System 501-20B-16

DIAGNOSIS AND TESTING (Continued)

Air Bag Control Module Wiring Harness control module circuit is broken, either by loss of
Connectors power or ground supply or electrical connector
disconnection.
Diagnostic evaluation of the supplemental
restraints system can be made through the data
link connector (DLC) and WDS to establish the
nature of the concern. Once the DTC is known
the appropriate course of action can be selected
from the Symptom Chart.

Inspection and Verification

1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of
mechanical or electrical damage.
Item Part Description
Number Visual Inspection Chart
1 - Connector shorting bar posi- Electrical
tions - Fuse(s)
- Electrical connector(s)
Both air bag control module connectors have - Circuit(s)
shorting bars on the harness side for air bag - Wiring harness
circuits. Pin numbers remain constant where pin - Air bag module(s)
positions have been removed due to the shorting - Bulb
bars.
3. If an obvious cause for an observed or
reported concern is found, correct the cause
Front Crash Sensor and Side Impact Sensors (if possible) before proceeding to the next
step.
Both the front crash sensor and the side impact
sensors contain an acceleration sensor, filter, 4. If the cause is not visually evident, connect
amplifier and an application specific integrated the diagnostic tool to the data link connector
circuit for signal transmitting. In the event of a and select the vehicle to be tested from the
collision, in excess of a predetermined limit, the diagnostic tool menu.
front crash sensor or a side impact sensor will 5. Retrieve the DTCs and refer to the Symptom
initiate a deployment request to the air bag Chart.
control module. The signal received by the air
bag control module is evaluated and processed
against stored data. The front crash sensor and
the side impact sensors do not process the
impact data.

Air Bag Warning Indicator

The air bag warning indicator is incorporated into
the instrument cluster, together with the
automatic detach detect (ADD) circuit. The air
bag warning indicator illuminates for six seconds
at key ON. If the system self-tests OK the
indicator extinguishes, if a fault is detected the
indicator flashes a corresponding fault code five
times and then remains illuminate continuously.
The ADD circuit is designed to illuminate the air
bag warning indicator continuously, if the air bag

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501-20B-17 Supplemental Restraint System 501-20B-17

DIAGNOSIS AND TESTING

Diagnostic Instructions - Air Bag and Safety Belt Pretensioner Supplemental

Restraint System (SRS)

3. If an obvious cause for an observed or

reported concern is found, correct the cause
Inspection and Verification (if possible) before proceeding to the next
1. Verify the customer concern by operating the step.
system. 4. If the cause is not visually evident, connect
2. Visually inspect for obvious signs of the diagnostic tool to the data link connector
mechanical or electrical damage. and select the vehicle to be tested from the
diagnostic tool menu.
Visual Inspection Chart 5. Retrieve the DTCs and refer to the Symptom
Electrical Chart.
- Fuse(s)
- Electrical connector(s)
- Circuit(s)
- Wiring harness
- Air bag module(s)
- Bulb
Symptom Chart

Condition Possible Sources Action

• No communication with the • Fuse. • Go to Pinpoint Test A.
module • DLC.
• Circuit(s).
• Air bag control module.
• DTC B1231: Longitudinal accel- • Crash data memory full. • Data cannot be cleared with
eration threshold exceeded. WDS. INSTALL a new air bag
Lamp flash code: 13 control module. REFER to Air
Bag Control Module in this sec-
tion. REPEAT the self-test,
CLEAR the DTCs.
• DTC B1342: Air bag control • Air bag control module. • INSTALL a new air bag control
module is defective. Lamp flash module. REFER to Air Bag
code: 12 Control Module in this section.
REPEAT the self-test, CLEAR
the DTCs.
• DTC B1869: Air bag warning • Circuit(s). • GO to Pinpoint Test B.
indicator open circuit or short to • Instrument cluster.
ground. Lamp flash code: con- • Air bag control module.
tinuous
• DTC B1870: Air bag warning • Circuit. • GO to Pinpoint Test C.
indicator short to battery. Lamp • Instrument cluster.
flash code: continuous
• DTC 1884: Passenger air bag • Circuit(s). • GO to Pinpoint Test D.
deactivation indicator inopera- • Air bag control module.
tive. Lamp flash code: 18 • Passenger air bag deactivation
indicator.

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501-20B-18 Supplemental Restraint System 501-20B-18

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• DTC B1890: Passenger air bag • Circuit(s). • GO to Pinpoint Test E.
deactivation indicator short to • Passenger air bag deactivation
battery. Lamp flash code: 18 indicator.
• DTC B1891: Air bag tone warn- • Air bag control module internal • INSTALL a new air bag control
ing indicator short to battery. fault. module. REFER to Air Bag
Lamp flash code: 53 Control Module in this section.
REPEAT the self-test, CLEAR
the DTCs.
• DTC B1892: Air bag tone warn- • Air bag control module internal • INSTALL a new air bag control
ing indicator circuit fault. Lamp fault. module. REFER to Air Bag
flash code: 53 Control Module in this section.
REPEAT the self-test, CLEAR
the DTCs.
• DTC B1921: Air bag diagnostic • Air bag control module internal • INSTALL a new air bag control
monitor ground circuit open. fault. module. REFER to Air Bag
Lamp flash code: 14 Control Module in this section.
REPEAT the self-test, CLEAR
the DTCs.
• DTC B2290 Error value 27: Oc- • Occupant classification sensor • INSTALL a new passenger seat
cupant Classification System module. cushion. REFER to Section 501-
module fault. Lamp flash code: 10. REPEAT the self-test,
16 CLEAR the DTCs.
• DTC B2290 Error value 26: Oc- • Circuit(s). • GO to Pinpoint Test F.
cupant Classification System
communications fault. Lamp
flash code: 16
• DTC B2290 Error value 25: Oc- • Occupant classification sensor • INSTALL a new passenger seat
cupant Classification System module. cushion. REFER to Section 501-
calibration fault. Lamp flash 10. REPEAT the self-test,
code: 16 CLEAR the DTCs.
• DTC B2290 Error value 24: Oc- • Occupant classification sensor. • INSTALL a new passenger seat
cupant Classification System cushion. REFER to Section 501-
sensing element fault. Lamp 10. REPEAT the self-test,
flash code: 16 CLEAR the DTCs.
• DTC B2292 Error value 31: • Circuit(s). • GO to Pinpoint Test G.
Driver safety belt pretensioner • Driver safety belt pretensioner.
circuit low resistance. Lamp
flash code: 33
• DTC B2292 Error value 30: • Circuit(s). • GO to Pinpoint Test H.
Driver safety belt pretensioner • Driver safety belt pretensioner.
open circuit. Lamp flash code:
33
• DTC B2292 Error value 29: • Circuit(s). • GO to Pinpoint Test I.
Driver safety belt pretensioner
short to battery. Lamp flash
code: 33

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501-20B-19 Supplemental Restraint System 501-20B-19

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• DTC B2292 Error value 28: • Circuit(s). • GO to Pinpoint Test J.
Driver safety belt pretensioner • Driver safety belt pretensioner.
short to ground. Lamp flash
code: 33
• DTC B2292 Error value 27: • Circuit(s). • GO to Pinpoint Test K.
Passenger safety belt preten- • Passenger safety belt preten-
sioner circuit low resistance. sioner.
Lamp flash code: 34
• DTC B2292 Error value 26: • Circuit(s). • GO to Pinpoint Test L.
Passenger safety belt preten- • Passenger safety belt preten-
sioner open circuit. Lamp flash sioner.
code: 34
• DTC B2292 Error value 25: • Circuit(s). • GO to Pinpoint Test M.
Passenger safety belt preten- • Passenger safety belt preten-
sioner short to battery. Lamp sioner.
flash code: 34
• DTC B2292 Error value 24: • Circuit(s). • GO to Pinpoint Test N.
Passenger safety belt preten- • Passenger safety belt preten-
sioner short to ground. Lamp sioner.
flash code: 34
• DTC B2293 Error value 31: • Driver air bag module. • GO to Pinpoint Test O.
Driver air bag first stage short to • Clockspring.
ground. Lamp flash code: 19 • Circuit(s).
• DTC B2293 Error value 30: • Clockspring. • GO to Pinpoint Test P.
Driver air bag first stage short to • Circuit(s).
battery. Lamp flash code: 19
• DTC B2293 Error value 29: • Driver air bag module. • GO to Pinpoint Test Q.
Driver air bag first stage open • Clockspring.
circuit. Lamp flash code: 19 • Circuit(s).
• DTC B2293 Error value 28: • Driver air bag module. • GO to Pinpoint Test R.
Driver air bag first stage circuit • Clockspring.
low resistance. Lamp flash • Circuit(s).
code: 19
• DTC B2293 Error value 27: • Passenger air bag module. • GO to Pinpoint Test S.
Passenger air bag first stage • Circuit(s).
short to ground. Lamp flash
code: 21
• DTC B2293 Error value 26: • Circuit(s). • GO to Pinpoint Test T.
Passenger air bag first stage
short to battery. Lamp flash
code: 21
• DTC B2293 Error value 25: • Passenger air bag module. • GO to Pinpoint Test U.
Passenger air bag first stage • Circuit(s).
open circuit. Lamp flash code:
21

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501-20B-20 Supplemental Restraint System 501-20B-20

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• DTC B2293 Error value 24: • Passenger air bag module. • GO to Pinpoint Test V.
Passenger air bag first stage • Circuit(s).
circuit low resistance. Lamp
flash code: 21
• DTC B2293 Error value 23: • Driver air bag module. • GO to Pinpoint Test W.
Driver air bag second stage • Clockspring.
short to ground. Lamp flash • Circuit(s).
code: 19
• DTC B2293 Error value 22: • Clockspring. • GO to Pinpoint Test X.
Driver air bag second stage • Circuit(s).
short to battery. Lamp flash
code: 19
• DTC B2293 Error value 21: • Driver air bag module. • GO to Pinpoint Test Y.
Driver air bag second stage • Clockspring.
open circuit. Lamp flash code: • Circuit(s).
19
• DTC B2293 Error value 20: • Driver air bag module. • GO to Pinpoint Test Z.
Driver air bag second stage cir- • Clockspring.
cuit low resistance. Lamp flash • Circuit(s).
code: 19
• DTC B2293 Error value 19: • Passenger air bag module. • GO to Pinpoint Test AA.
Passenger air bag second stage • Circuit(s).
short to ground. Lamp flash
code: 21
• DTC B2293 Error value 18: • Circuit(s). • GO to Pinpoint Test AB.
Passenger air bag second stage
short to battery. Lamp flash
code: 21
• DTC B2293 Error value 17: • Passenger air bag module. • GO to Pinpoint Test AC.
Passenger air bag second stage • Circuit(s).
open circuit. Lamp flash code:
21
• DTC B2293 Error value 16: • Passenger air bag module. • GO to Pinpoint Test AD.
Passenger air bag second stage • Circuit(s).
circuit low resistance. Lamp
flash code: 21
• DTC B2294 Error value 31: • Circuit(s). • GO to Pinpoint Test AE.
Driver side air curtain circuit
short to battery. Lamp flash
code: 24
• DTC B2294 Error value 30: • Driver side air curtain module. • GO to Pinpoint Test AF.
Driver side air curtain circuit • Circuit(s).
short to ground. Lamp flash
code: 24
• DTC B2294 Error value 29: • Driver side air curtain module. • GO to Pinpoint Test AG.
Driver side air curtain circuit • Circuit(s).
open circuit. Lamp flash code:
24

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501-20B-21 Supplemental Restraint System 501-20B-21

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• DTC B2294 Error value 28: • Driver side air curtain module. • GO to Pinpoint Test AH.
Driver side air curtain circuit low • Circuit(s).
resistance on squib. Lamp flash
code: 24
• DTC B2294 Error value 27: • Circuit(s). • GO to Pinpoint Test AI.
Passenger side air curtain circuit
short to battery. Lamp flash
code: 25
• DTC B2294 Error value 26: • Passenger side air curtain • GO to Pinpoint Test AJ.
Passenger side air curtain circuit module.
short to ground. Lamp flash • Circuit(s).
code: 25
• DTC B2294 Error value 25: • Passenger side air curtain • GO to Pinpoint Test AK.
Passenger side air curtain circuit module.
open circuit. Lamp flash code: • Circuit(s).
25
• DTC B2294 Error value 24: • Passenger side air curtain • GO to Pinpoint Test AL.
Passenger side air curtain circuit module.
low resistance on squib. Lamp • Circuit(s).
flash code: 25
• DTC B2295 Error value 31: • Circuit(s). • GO to Pinpoint Test AM.
Driver side air bag circuit short
to battery. Lamp flash code: 22
• DTC B2295 Error value 30: • Driver side air bag module. • GO to Pinpoint Test AN.
Driver side air bag circuit short • Circuit(s).
to ground. Lamp flash code: 22
• DTC B2295 Error value 29: • Driver side air bag module. • GO to Pinpoint Test AO.
Driver side air bag circuit open • Circuit(s).
circuit. Lamp flash code: 22
• DTC B2295 Error value 28: • Driver side air bag module. • GO to Pinpoint Test AP.
Driver side air bag circuit low re- • Circuit(s).
sistance on squib. Lamp flash
code: 22
• DTC B2295 Error value 27: • Circuit(s). • GO to Pinpoint Test AQ.
Passenger side air bag circuit
short to battery. Lamp flash
code: 23
• DTC B2295 Error value 26: • Passenger side air bag module. • GO to Pinpoint Test AR.
Passenger side air bag circuit • Circuit(s).
short to ground. Lamp flash
code: 23
• DTC B2295 Error value 25: • Passenger side air bag module. • GO to Pinpoint Test AS.
Passenger side air bag circuit • Circuit(s).
open circuit. Lamp flash code:
23

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501-20B-22 Supplemental Restraint System 501-20B-22

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action
• DTC B2295 Error value 24: • Passenger side air bag module. • GO to Pinpoint Test AT.
Passenger side air bag circuit • Circuit(s).
low resistance on squib. Lamp
flash code: 23
• DTC B2296 Error value 31: • Circuit(s). • GO to Pinpoint Test AU.
Driver side impact sensor com-
munications fault. Lamp flash
code: 43
• DTC B2296 Error value 30: • Driver side impact sensor. • INSTALL a new driver side im-
Driver side impact sensor inter- pact sensor. REFER to Side
nal fault. Lamp flash code: 43 Impact Sensor in this section.
REPEAT the self-test, CLEAR
the DTCs.
• DTC B2296 Error value 29: • Circuit(s). • GO to Pinpoint Test AV.
Passenger side impact sensor
communications fault. Lamp
flash code: 44
• DTC B2296 Error value 28: • Passenger side impact sensor. • INSTALL a new passenger side
Passenger side impact sensor impact sensor. REFER to Side
internal fault. Lamp flash code: Impact Sensor in this section.
44 REPEAT the self-test, CLEAR
the DTCs.
• DTC B2296 Error value 19: • Circuit(s). • GO to Pinpoint Test AW.
Crash sensor communications
fault. Lamp flash code: 42
• DTC B2296 Error value 18: • Crash sensor. • INSTALL a new crash sensor.
Crash sensor internal fault. REFER to Crash Sensor in this
Lamp flash code: 42 section. REPEAT the self-test,
CLEAR the DTCs.
• DTC B2434: Driver safety belt • Driver safety belt buckle switch. • GO to Pinpoint Test AX.
buckle switch short circuit to • Circuit(s).
ground. Lamp flash code: 51
• DTC B2435: Driver safety belt • Driver safety belt buckle switch. • GO to Pinpoint Test AY.
buckle switch resistance out of • Circuit(s).
range. Lamp flash code: 51
• DTC B2438: Passenger safety • Passenger safety belt buckle • GO to Pinpoint Test AZ.
belt buckle switch short circuit to switch.
ground. Lamp flash code: 52 • Circuit(s).
• DTC B2439: Passenger safety • Passenger safety belt buckle • GO to Pinpoint Test BA.
belt buckle switch resistance out switch.
of range. Lamp flash code: 52 • Circuit(s).
• DTC B2477: Air bag control • Air bag control module. • CONFIGURE the air bag control
module configuration failure. module. REFER to Section 418-
Lamp flash code: 54 01. REPEAT the self-test,
CLEAR the DTCs.

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501-20B-23 Supplemental Restraint System 501-20B-23

DIAGNOSIS AND TESTING (Continued)

Condition Possible Sources Action

• DTC B2691: Driver safety belt • Driver safety belt buckle switch. • GO to Pinpoint Test BB.
buckle switch open circuit or • Circuit(s).
short to battery. Lamp flash
code: 51
• DTC B2692: Passenger safety • Passenger safety belt buckle • GO to Pinpoint Test BC.
belt buckle switch open circuit switch.
short to battery. Lamp flash • Circuit(s).
code: 52
• DTC C1414: Incorrect Module • Air bag control module. • INSTALL a new air bag control
Design Level. Lamp flash code: module. REFER to Air Bag
15 Control Module in this section.
REPEAT the self-test, CLEAR
the DTCs.
• DTC C1947: Seat position sen- • Seat position sensor. • GO to Pinpoint Test BD.
sor short circuit to ground or bat- • Circuit(s).
tery. Lamp flash code: 49
• DTC C1948: Seat position sen- • Seat position sensor. • GO to Pinpoint Test BE.
sor resistance out of range. • Circuit(s).
Lamp flash code: 49
• DTC C1981: Seat position sen- • Seat position sensor. • GO to Pinpoint Test BF.
sor open circuit. Lamp flash • Circuit(s).
code: 49
• Air bag control module discon- • Air bag control module • GO to Pinpoint Test BG.
nected or inoperative. Lamp • Circuit(s).
flash code: continuous

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501-20B-24 Supplemental Restraint System 501-20B-24

DIAGNOSIS AND TESTING

Pinpoint Tests - Air Bag and Safety Belt Pretensioner Supplemental Restraint
System (SRS)

Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE MODULE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
A1: CHECK THE WDS IS COMMUNICATING THROUGH THE DATA LINK CONNECTOR (DLC)
1 Select an alternative system to check the DLC.
• Is WDS able to communicate with the selected
system?
→ Yes
GO to A2
→ No
CHECK the DLC. For additional information,
refer to the Wiring Diagrams.
A2: CHECK THE AIR BAG WARNING INDICATOR
1 Key in ON position.
2 The air bag warning indicator should illuminate
when the ignition is in the ON position for six
seconds and then go out. If a fault is present,
the air bag warning light will then begin to
flash.
• Is the warning indicator operating?
→ Yes
GO to A3
→ No
CHECK the instrument cluster. For addi-
tional information, refer to the Wiring Dia-
grams.
A3: CHECK THE DLC CIRCUIT
1 Key in OFF position.
2 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
3 Disconnect Air Bag Control Module C490.
4 Measure the resistance between the DLC
C418 pin 7, circuit 8-EE10 (WH/BK) and the air
bag control module C490 pin 11, circuit 8-EE7
(WH/RD) harness side.

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501-20B-25 Supplemental Restraint System 501-20B-25

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 5 ohms?

→ Yes
If the air bag warning indicator is flashing,
count the lamp flash code and refer to the
Symptom Chart in this section. INSTALL a
new air bag control module. REFER to Air
Bag Control Module in this section.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuit 8-EE7 (WH/RD) or 8-EE10
(WH/BK). REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST B: DTC B1869: AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO
GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE AIR BAG WARNING INDICATOR
1 Key in ON position.
2 Check the air bag warning indicator.
• Is the air bag warning indicator illuminated con-
tinuously?
→ Yes
GO to B2
→ No
GO to B5
B2: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow
this instruction may result in personal injury.
1 Key in OFF position.

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501-20B-26 Supplemental Restraint System 501-20B-26

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
3 Disconnect Air Bag Control Module C490.
4 Disconnect Instrument Cluster C449.
5 Measure the resistance between the instru-
ment cluster C449 pin 9, circuit 91S-JA14
(BK/GN) and the air bag control module C490
pin 19, circuit 91S-JA14 (BK/GN).

• Is the resistance less than 5 ohms?

→ Yes
GO to B3
→ No
REPAIR circuit 91S-JA14 (BK/GN).
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
B3: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1 Connect Instrument Cluster C449.
2 Install a fused (7.5A) jumper wire between the
air bag control module C490 pin 19, circuit
91S-JA14 (BK/GN) harness side and ground.
- Turn the ignition to the ON position.

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501-20B-27 Supplemental Restraint System 501-20B-27

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the air bag warning indicator illuminated?

→ Yes
INSTALL a new instrument cluster. REFER
to Section 413-01. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
→ No
GO to B4
B4: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1 With the fused (7.5A) jumper wire between the
air bag control module C490 pin 19, circuit
91S-JA14 (BK/GN) harness side and ground.
- Disconnect the fused jumper wire from the
ground.

• Is the air bag warning indicator illuminated?

→ Yes
INSTALL a new air bag control module.
REFER to Air Bag Control Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
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501-20B-28 Supplemental Restraint System 501-20B-28

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
B5: CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow
this instruction may result in personal injury.
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Check the instrument cluster warning indica-
tors.
• Are the warning indicators illuminated when the
ignition is switched to the ON position?
→ Yes
GO to B6
→ No
CHECK the instrument cluster. For addi-
tional information, refer to Wiring Diagrams.
B6: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Measure the resistance between the air bag
control module C490 pin 19, circuit 91S-JA14
(BK/GN) harness side and ground.

• Is the resistance greater than 10,000 ohms?

→ Yes

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501-20B-29 Supplemental Restraint System 501-20B-29

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK the air bag warning indicator LED.
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuit 91S-JA14 (BK/GN).
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
PINPOINT TEST C: DTC B1870: AIR BAG WARNING INDICATOR SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
C1: CHECK THE AIR BAG WARNING INDICATOR
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Instrument Cluster C449.
4 Key in ON position.
5 Measure the voltage between the air bag con-
trol module C490 pin 19, circuit 91S-JA14
(BK/GN) harness side and ground.

• Is any voltage present?

→ Yes

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501-20B-30 Supplemental Restraint System 501-20B-30

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
CHECK the instrument cluster. For addi-
tional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST D: DTC B1884: PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
D1: CHECK THE PAD INDICATOR FUNCTION
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C490 pin 15.
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Air Bag Control Module C490.
3 Install a fused (7.5A) jumper wire between the
air bag control module C490 pin 15, circuit
91S-JA47 (BK/OG) harness side and ground.
- Turn the ignition to the ON position.

• Is the PAD indicator illuminated?

→ Yes

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501-20B-31 Supplemental Restraint System 501-20B-31

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new air bag control module.
REFER to Air Bag Control Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to D2
D2: CHECK THE PAD INDICATOR SUPPLY CIRCUIT
1 Key in OFF position.
2 Disconnect PAD Indicator C417.
3 Key in ON position.
4 Measure the voltage between the PAD indica-
tor C417 pin 8, circuit 15-JA47 (GN/RD) har-
ness side and ground.

• Is the voltage greater than 9 volts?

→ Yes
GO to D3
→ No
REPAIR circuit 15-JA47 (GN/RD). REPEAT
the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
D3: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the air bag
control module C490 pin 15, circuit 91S-JA47
(BK/OG) and the PAD warning indicator C417
pin 4, circuit 91S-JA47 (BK/OG) harness side.

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501-20B-32 Supplemental Restraint System 501-20B-32

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance less than 5 ohms?

→ Yes
INSTALL a new PAD indicator. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR circuit 91S-JA47 (BK/OG).
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
PINPOINT TEST E: DTC B1890: PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
E1: CHECK THE PAD INDICATOR CIRCUIT
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C490 pin 15.
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Air Bag Control Module C490.
3 Disconnect PAD Indicator C417.
4 Key in ON position.
5 Measure the voltage between the air bag con-
trol module C490 pin 15, circuit 91S-JA47
(BK/OG) harness side and ground.

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501-20B-33 Supplemental Restraint System 501-20B-33

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
INSTALL a new PAD indicator. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
PINPOINT TEST F: DTC B2290 ERROR VALUE 26: OCCUPANT CLASSIFICATION SYSTEM
COMMUNICATIONS FAULT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
F1: CHECK THE OCCUPANT CLASSIFICATION SENSOR SUPPLY CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Passenger Underseat Air Bag
Simulator.
3 Key in ON position.
4 Measure the voltage between the occupant
classification sensor C61 pin 2, circuit 15-JA52
(GN/BK) harness side and ground.

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501-20B-34 Supplemental Restraint System 501-20B-34

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the voltage greater than 9 volts?

→ Yes
GO to F2
→ No
REPAIR circuit 15-JA52 (GN/BK). REPEAT
the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
F2: CHECK THE OCCUPANT CLASSIFICATION SENSOR GROUND CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the occupant
classification sensor C61 pin 1, circuit 91-JA52
(BK/GN) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes
GO to F3
→ No

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501-20B-35 Supplemental Restraint System 501-20B-35

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuit 91-JA52 (BK/GN). REPEAT
the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
F3: CHECK THE CIRCUITS BETWEEN THE OCCUPANT CLASSIFICATION SENSOR AND THE
AIR BAG CONTROL MODULE FOR CONTINUITY
1 Disconnect Air Bag Control Module.
2 Measure the resistance between:
- the air bag control module C491 pin 17,
circuit 8-JA52 (WH/GN) and the occupant
classification sensor C61 pin 3, circuit 8-JA52
(WH/GN) harness side; and
- the air bag control module C491 pin 18, cir-
cuit 9-JA52 (BN/GN) and the occupant classi-
fication sensor C61 pin 4, circuit 9-JA52
(BN/GN) harness side.

• Are the resistances less than 5 ohms?

→ Yes
GO to F4
→ No
REPAIR circuit 8-JA52 (WH/GN) or circuit 9-
JA52 (BN/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
F4: CHECK THE OCCUPANT CLASSIFICATION SYSTEM FOR A SHORT TO BATTERY OR
IGNITION
1 Key in ON position.
2 Measure the voltage between:
- the air bag control module C491 pin 17,
circuit 8-JA52 (WH/GN) harness side and
ground; and
- the air bag control module C491 pin 18, cir-
cuit 9-JA52 (BN/GN) harness side and
ground.

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501-20B-36 Supplemental Restraint System 501-20B-36

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to F5
F5: CHECK THE OCCUPANT CLASSIFICATION SYSTEM FOR A SHORT GROUND
1 Key in OFF position.
2 Measure the resistance between:
- the air bag control module C491 pin 17,
circuit 8-JA52 (WH/GN) harness side and
ground; and
- the air bag control module C491 pin 18, cir-
cuit 9-JA52 (BN/GN) harness side and
ground.

• Are the resistances greater than 10,000 ohms?

→ Yes

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501-20B-37 Supplemental Restraint System 501-20B-37

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Install a new passenger seat cushion.
REFER to Section 501-10. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST G: DTC B2292 ERROR VALUE 31: DRIVER SAFETY BELT PRETENSIONER
CIRCUIT LOW RESISTANCE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
G1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to G2
→ No
GO to G3
G2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER
1 Key in OFF position.
2 Disconnect Driver Underseat Air Bag Simula-
tor.
3 Connect Driver Underseat Air Bag Connector
C60.
4 Key in ON position.
5 Carry out the self-test.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No

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501-20B-38 Supplemental Restraint System 501-20B-38

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new driver safety belt preten-
sioner. REFER to Section 501-20A / 501-
20B. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
G3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between the air bag
control module C491 pin 31, circuit 15S-JA33
(GN/BU) and pin 32, circuit 91S-JA33 (BK/BU)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA33 (GN/BU) and
91S-JA33 (BK/BU). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST H: DTC B2292 ERROR VALUE 30: DRIVER SAFETY BELT PRETENSIONER
OPEN CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-39 Supplemental Restraint System 501-20B-39

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
H1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to H2
→ No
GO to H3
H2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER
1 Key in OFF position.
2 Disconnect Driver Underseat Air Bag Simula-
tor.
3 Connect Driver Underseat Air Bag Connector
C60.
4 Key in ON position.
5 Carry out the self-test.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver safety belt preten-
sioner. REFER to Section 501-20A / 501-
20B. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
H3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.

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501-20B-40 Supplemental Restraint System 501-20B-40

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C491 pin 31,
circuit 15S-JA33 (GN/BU) and the driver
safety belt pretensioner C60 pin 7, circuit
15S-JA33 (GN/BU) harness side; and
- the air bag control module C491 pin 32, cir-
cuit 91S-JA33 (BK/BU) and the driver safety
belt pretensioner C60 pin 8, circuit 91S-JA33
(BK/BU) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA33 (GN/BU) and
91S-JA33 (BK/BU). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST I: DTC B2292 ERROR VALUE 29: DRIVER SAFETY BELT PRETENSIONER
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
I1: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY OR
IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Air Bag Control Module C491.

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501-20B-41 Supplemental Restraint System 501-20B-41

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Key in ON position.
5 Measure the voltage between:
- the air bag control module C491 pin 31,
circuit 15S-JA33 (GN/BU) harness side and
ground; and
- the air bag control module C491 pin 32, 91S-
JA33 (BK/BU) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
PINPOINT TEST J: DTC B2292 ERROR VALUE 28: DRIVER SAFETY BELT PRETENSIONER
SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
J1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.

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501-20B-42 Supplemental Restraint System 501-20B-42

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to J2
→ No
GO to J3
J2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER
1 Key in OFF position.
2 Disconnect Driver Underseat Air Bag Simula-
tor.
3 Connect Driver Underseat Air Bag Connector
C60.
4 Key in ON position.
5 Carry out the self-test.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver safety belt preten-
sioner. REFER to Section 501-20A / 501-
20B. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
J3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the air bag control module C491 pin 31,
circuit 15S-JA33 (GN/BU) harness side and
ground; and
- the air bag control module C491 pin 32, 91S-
JA33 (BK/BU) harness side and ground.

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501-20B-43 Supplemental Restraint System 501-20B-43

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST K: DTC B2292 ERROR VALUE 27: PASSENGER SAFETY BELT PRETENSIONER
CIRCUIT LOW RESISTANCE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
K1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in OFF position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to K2
→ No
GO to K3
K2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
1 Key in OFF position.
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501-20B-44 Supplemental Restraint System 501-20B-44

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Passenger Underseat Air Bag
Simulator.
3 Connect Passenger Underseat Air Bag Con-
nector C61.
4 Key in ON position.
5 Carry out the self-test.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger safety belt pre-
tensioner. REFER to Section 501-20A / 501-
20B. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
K3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between the air bag
control module C491 pin 33, circuit 15S-JA34
(GN/OG) and pin 34, circuit 91S-JA34 (BK/RD)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
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501-20B-45 Supplemental Restraint System 501-20B-45

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR circuits 15S-JA34 (GN/OG) and
91S-JA34 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST L: DTC B2292 ERROR VALUE 26: PASSENGER SAFETY BELT PRETENSIONER
OPEN CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
L1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to L2
→ No
GO to L3
L2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
1 Key in OFF position.
2 Disconnect Passenger Underseat Air Bag
Simulator.
3 Connect Passenger Underseat Air Bag Con-
nector C61.
4 Key in ON position.
5 Carry out the self-test.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger safety belt pre-
tensioner. REFER to Section 501-20A / 501-
20B. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.

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501-20B-46 Supplemental Restraint System 501-20B-46

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
L3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between:
- the air bag control module C491 pin 33,
circuit 15S-JA34 (GN/OG) and the passenger
safety belt pretensioner C61 pin 7, circuit
15S-JA34 (GN/OG) harness side; and
- the air bag control module C491 pin 34, cir-
cuit 91S-JA34 (BK/RD) and the passenger
safety belt pretensioner C61 pin 8, circuit
91S-JA34 (BK/RD) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA34 (GN/OG) and
91S-JA34 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST M: DTC B2292 ERROR VALUE 25: PASSENGER SAFETY BELT
PRETENSIONER SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-47 Supplemental Restraint System 501-20B-47

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
M1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY OR
IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in OFF position.
3 Disconnect Air Bag Control Module C491.
4 Disconnect Passenger Underseat Air Bag
Simulator.
5 Key in ON position.
6 Measure the voltage between:
- the air bag control module C491 pin 33,
circuit 15S-JA34 (GN/OG) harness side and
ground; and
- the air bag control module C491 pin 34, 91S-
JA34 (BK/RD) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.

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501-20B-48 Supplemental Restraint System 501-20B-48

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST N: DTC B2292 ERROR VALUE 24: PASSENGER SAFETY BELT PRETENSIONER
SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
N1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to N2
→ No
GO to N3
N2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
1 Key in OFF position.
2 Disconnect Passenger Underseat Air Bag
Simulator.
3 Connect Passenger Underseat Air Bag Con-
nector C61.
4 Key in ON position.
5 Carry out the self-test.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger safety belt pre-
tensioner. REFER to Section 501-20A / 501-
20B. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
N3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.

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501-20B-49 Supplemental Restraint System 501-20B-49

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C491 pin 33,
circuit 15S-JA34 (GN/OG) harness side and
ground; and
- the air bag control module C491 pin 34, 91S-
JA34 (BK/RD) harness side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST O: DTC B2293 ERROR VALUE 31: DRIVER AIR BAG FIRST STAGE SHORT TO
GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
O1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?

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501-20B-50 Supplemental Restraint System 501-20B-50

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to O2
→ No
GO to O3
O2: CHECK THE DRIVER AIR BAG MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.
5 Connect the Test and Deployment Lead to the
driver air bag module - second stage.
6 Measure the resistance between each of the
terminals and the air bag module casing.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
O3: CHECK THE DRIVER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.

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501-20B-51 Supplemental Restraint System 501-20B-51

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect Driver Air Bag Module First Stage
Simulator.
4 Measure the resistance between:
- the air bag control module C490 pin 1, circuit
15S-JA8 (GN/RD) harness side and ground;
and
- the air bag control module C490 pin 2, circuit
91S- JA8 (BK/OG) harness side and ground.
5 Turn the steering wheel from lock to lock and
note the resistance readings.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
GO to O4
O4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
1 Disconnect Clockspring C413.
2 Measure the resistance between:
- the air bag control module C490 pin 1, circuit
15S-JA8 (GN/RD) harness side and ground;
and
- the air bag control module C490 pin 2, circuit
91S- JA8 (BK/OG) harness side and ground.
3 Turn the steering wheel from lock to lock and
note the resistance readings.

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501-20B-52 Supplemental Restraint System 501-20B-52

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST P: DTC B2293 ERROR VALUE 30: DRIVER AIR BAG FIRST STAGE SHORT TO
BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
P1: CHECK THE DRIVER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Driver Air Bag Module First Stage
Simulator.
3 Disconnect Air Bag Control Module C490.
4 Key in ON position.

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501-20B-53 Supplemental Restraint System 501-20B-53

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
5 Measure the voltage between:
- the air bag control module C490 pin 1, circuit
15S-JA8 (GN/RD) harness side and ground;
and
- the air bag control module C490 pin 2, circuit
91S- JA8 (BK/OG) harness side and ground.

• Is any voltage present?

→ Yes
GO to P2
→ No
CONNECT the driver air bag module first
stage simulator and the air bag control
module. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
P2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION
1 Key in OFF position.
2 Disconnect Clockspring C413.
3 Key in ON position.
4 Measure the voltage between:
- the air bag control module C490 pin 1, circuit
15S-JA8 (GN/RD) harness side and ground;
and
- the air bag control module C490 pin 2, circuit
91S- JA8 (BK/OG) harness side and ground.

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501-20B-54 Supplemental Restraint System 501-20B-54

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
PINPOINT TEST Q: DTC B2293 ERROR VALUE 29: DRIVER AIR BAG FIRST STAGE OPEN
CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
Q1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to Q2
→ No
GO to Q3

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501-20B-55 Supplemental Restraint System 501-20B-55

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Q2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
driver air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
Q3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Clockspring C413.

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501-20B-56 Supplemental Restraint System 501-20B-56

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C490 pin 1, circuit
15S - JA8 (GN/RD) and the Clockspring C413
pin 9, circuit 15S-JA8 (GN/RD) harness side;
and
- the air bag control module C490 pin 2, circuit
91S-JA8 (BK/OG) and the Clockspring C413
pin 8, circuit 91S-JA8 (BK/OG) harness side.

• Are the resistances less than 5 ohms?

→ Yes
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR circuits 15S-JA8 (GN/RD) and
91S-JA8 (BK/OG). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST R: DTC B2293 ERROR VALUE 28: DRIVER AIR BAG FIRST STAGE CIRCUIT
LOW RESISTANCE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
R1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.

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501-20B-57 Supplemental Restraint System 501-20B-57

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the system prove out correctly?

→ Yes
GO to R2
→ No
GO to R3
R2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
driver air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
R3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C490 pin 1.
1 Key in OFF position.
2 Disconnect Clockspring C413.

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501-20B-58 Supplemental Restraint System 501-20B-58

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect Air Bag Control Module C490.
4 Measure the resistance between the air bag
control module C490 pin 1, circuit 15S-JA8
(GN/RD) and pin 2, circuit 91S-JA8 (BK/OG)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR circuits 15S-JA8 (GN/RD) and
91S-JA8 (BK/OG). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST S: DTC B2293 ERROR VALUE 27: PASSENGER AIR BAG FIRST STAGE SHORT
TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
S1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes

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501-20B-59 Supplemental Restraint System 501-20B-59

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to S2
→ No
GO to S3
S2: CHECK THE PASSENGER AIR BAG MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.
5 Connect the Test and Deployment Lead to the
passenger air bag module - second stage.
6 Measure the resistance between each of the
terminals and the air bag module casing.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
S3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.

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501-20B-60 Supplemental Restraint System 501-20B-60

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect Passenger Air Bag Module First
Stage Simulator.
4 Measure the resistance between:
- the air bag control module C490 pin 3, circuit
15S-JA8 (GN/YE) harness side and ground;
and
- the air bag control module C490 pin 4, circuit
91S- JA32 (BK/WH) harness side and
ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST T: DTC B2293 ERROR VALUE 26: PASSENGER AIR BAG FIRST STAGE SHORT
TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
T1: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.

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501-20B-61 Supplemental Restraint System 501-20B-61

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Passenger Air Bag Module First
Stage Simulator.
3 Disconnect Air Bag Control Module C490.
4 Key in ON position.
5 Measure the voltage between:
- the air bag control module C490 pin 3, circuit
15S-JA32 (GN/YE) harness side and ground;
and
- the air bag control module C490 pin 4, circuit
91S- JA32 (BK/WH) harness side and
ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
CONNECT the passenger air bag module
first stage simulator and the air bag control
module. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST U: DTC B2293 ERROR VALUE 25: PASSENGER AIR BAG FIRST STAGE OPEN
CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-62 Supplemental Restraint System 501-20B-62

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
U1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to U2
→ No
GO to U3
U2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
passenger air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No

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501-20B-63 Supplemental Restraint System 501-20B-63

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
U3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR OPEN CIRCUIT
OR HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Passenger Air Bag First Stage
Simulator.
4 Measure the resistance between:
- the air bag control module C490 pin 3, circuit
15S-JA32 (GN/YE) and the passenger air bag
module C481 pin 1, circuit 15S-JA32 (GN/YE)
harness side; and
- the air bag control module C490 pin 4, circuit
91S-JA32 (BK/WH) and the passenger air
bag module C481 pin 2, circuit 91S-JA32
(BK/WH) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA32 (GN/YE) and
91S-JA32 (BK/WH). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.

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501-20B-64 Supplemental Restraint System 501-20B-64

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST V: DTC B2293 ERROR VALUE 24: PASSENGER AIR BAG FIRST STAGE
CIRCUIT LOW RESISTANCE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
V1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to V2
→ No
GO to V3
V2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
passenger air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes

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501-20B-65 Supplemental Restraint System 501-20B-65

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
V3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR LOW
RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C490 pin 3.
1 Key in OFF position.
2 Disconnect Passenger Air Bag First Stage
Simulator.
3 Disconnect Air Bag Control Module C490.
4 Measure the resistance between the air bag
control module C490 pin 3, circuit 15S-JA32
(GN/YE) and pin 4, circuit 91S-JA32 (BK/WH)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA32 (GN/YE) and
91S-JA32 (BK/WH). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.

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501-20B-66 Supplemental Restraint System 501-20B-66

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST W: DTC B2293 ERROR VALUE 23: DRIVER AIR BAG SECOND STAGE SHORT
TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
W1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to W2
→ No
GO to W3
W2: CHECK THE DRIVER AIR BAG MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.
5 Connect the Test and Deployment Lead to the
driver air bag module - second stage.
6 Measure the resistance between each of the
terminals and the air bag module casing.

• Are the resistances greater than 10,000 ohms?

→ Yes

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501-20B-67 Supplemental Restraint System 501-20B-67

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
W3: CHECK THE DRIVER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT TO
GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Driver Air Bag Module Second
Stage Simulator.
4 Measure the resistance between:
- the air bag control module C490 pin 5, circuit
15S-JA48 (GN/BK) harness side and ground;
and
- the air bag control module C490 pin 6, circuit
91S- JA8 (BK/GN) harness side and ground.
5 Turn the steering wheel from lock to lock and
note the resistance readings.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
GO to W4
W4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
1 Disconnect Clockspring C413.

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501-20B-68 Supplemental Restraint System 501-20B-68

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
- the air bag control module C490 pin 5, circuit
15S-JA48 (GN/BK) harness side and ground;
and
- the air bag control module C490 pin 6, circuit
91S- JA8 (BK/GN) harness side and ground.
3 Turn the steering wheel from lock to lock and
note the resistance readings.

• Are the resistances greater than 10,000 ohms?

→ Yes
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST X: DTC B2293 ERROR VALUE 22: DRIVER AIR BAG SECOND STAGE SHORT
TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
X1: CHECK THE DRIVER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.

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501-20B-69 Supplemental Restraint System 501-20B-69

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disconnect Driver Air Bag Module Second
Stage Simulator.
3 Disconnect Air Bag Control Module C490.
4 Key in ON position.
5 Measure the voltage between:
- the air bag control module C490 pin 5, circuit
15S-JA48 (GN/BK) harness side and ground;
and
- the air bag control module C490 pin 6, circuit
91S- JA48 (BK/GN) harness side and ground.

• Is any voltage present?

→ Yes
GO to X2
→ No
CONNECT the driver air bag module sec-
ond stage simulator and the air bag control
module. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
X2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION
1 Key in OFF position.
2 Disconnect Clockspring C413.
3 Key in ON position.
4 Measure the voltage between:
- the air bag control module C490 pin 5, circuit
15S-JA48 (GN/BK) harness side and ground;
and
- the air bag control module C490 pin 6, circuit
91S- JA48 (BK/GN) harness side and ground.

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501-20B-70 Supplemental Restraint System 501-20B-70

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
PINPOINT TEST Y: DTC B2293 ERROR VALUE 21: DRIVER AIR BAG SECOND STAGE OPEN
CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
Y1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to Y2
→ No
GO to Y3

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501-20B-71 Supplemental Restraint System 501-20B-71

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
Y2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
driver air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
Y3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Clockspring C143.

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501-20B-72 Supplemental Restraint System 501-20B-72

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C490 pin 5, circuit
15S-JA48 (GN/BK) and the Clockspring C413
pin 2, circuit 15S-JA48 (GN/BK) harness side;
and
- the air bag control module C490 pin 6, circuit
91S-JA48 (BK/GN) and the Clockspring C413
pin 1, circuit 91S-JA48 (BK/GN) harness side.

• Are the resistances less than 5 ohms?

→ Yes
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR circuits 15S-JA48 (GN/BK) and
91S-JA48 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST Z: DTC B2293 ERROR VALUE 20: DRIVER AIR BAG SECOND STAGE CIRCUIT
LOW RESISTANCE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
Z1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.

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501-20B-73 Supplemental Restraint System 501-20B-73

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the system prove out correctly?

→ Yes
GO to Z2
→ No
GO to Z3
Z2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
driver air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
driver air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver air bag module.
REFER to Driver Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
Z3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C490 pin 5.
1 Key in OFF position.
2 Disconnect Clockspring C413.

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501-20B-74 Supplemental Restraint System 501-20B-74

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Disconnect Air Bag Control Module C490.
4 Measure the resistance between the air bag
control module C490 pin 5, circuit 15S-JA48
(GN/BK) and pin 6, circuit 91S-JA48 (BK/GN)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
INSTALL a new Clockspring. REFER to
Clockspring in this section. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
REPAIR circuits 15S-JA48 (GN/BK) and
91S-JA48 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AA: DTC B2293 ERROR VALUE 19: PASSENGER AIR BAG SECOND STAGE
SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AA1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes

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501-20B-75 Supplemental Restraint System 501-20B-75

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to AA2
→ No
GO to AA3
AA2: CHECK THE PASSENGER AIR BAG MODULE
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.
5 Connect the Test and Deployment Lead to the
passenger air bag module - second stage.
6 Measure the resistance between each of the
terminals and the air bag module casing.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AA3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT
TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Passenger Air Bag Module Second
Stage Simulator.

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501-20B-76 Supplemental Restraint System 501-20B-76

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C490 pin 13,
circuit 15S-JA31 (GN/BK) harness side and
ground; and
- the air bag control module C490 pin 14, cir-
cuit 91S- JA31 (BK/WH) harness side and
ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AB: DTC B2293 ERROR VALUE 18: PASSENGER AIR BAG SECOND STAGE
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AB1: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT
TO BATTERY OR IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Passenger Air Bag Module Second
Stage Simulator.
3 Disconnect Air Bag Control Module C490.

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501-20B-77 Supplemental Restraint System 501-20B-77

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Key in ON position.
5 Measure the voltage between:
- the air bag control module C490 pin 13,
circuit 15S-JA31 (GN/WH) harness side and
ground; and
- the air bag control module C490 pin 14, cir-
cuit 91S- JA31 (BK/WH) harness side and
ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
CONNECT the passenger air bag module
second stage simulator and the air bag con-
trol module. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.
PINPOINT TEST AC: DTC B2293 ERROR VALUE 17: PASSENGER AIR BAG SECOND STAGE
OPEN CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AC1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.

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501-20B-78 Supplemental Restraint System 501-20B-78

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AC2
→ No
GO to AC3
AC2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
passenger air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.

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501-20B-79 Supplemental Restraint System 501-20B-79

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AC3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR OPEN
CIRCUIT OR HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C490.
3 Disconnect Passenger Air Bag Module Second
Stage Simulator.
4 Measure the resistance between:
- the air bag control module C490 pin 13,
circuit 15S-JA31 (GN/WH) and the passenger
air bag module C482 pin 1, circuit 15S-JA31
(GN/WH) harness side; and
- the air bag control module C490 pin 14, cir-
cuit 91S-JA31 (BK/WH) and the passenger
air bag module C482 pin 2, circuit 91S-JA31
(BK/WH) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA31 (GN/WH) and
91S-JA31 (BK/WH). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AD: DTC B2293 ERROR VALUE 16: PASSENGER AIR BAG SECOND STAGE
CIRCUIT LOW RESISTANCE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-80 Supplemental Restraint System 501-20B-80

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AD1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AD2
→ No
GO to AD3
AD2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
5 Connect the Test and Deployment Lead to the
passenger air bag module - second stage.
6 Measure the resistance of the air bag module
squib.

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No

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501-20B-81 Supplemental Restraint System 501-20B-81

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new passenger air bag module.
REFER to Passenger Air Bag Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AD3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR LOW
RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C490 pin 13.
1 Key in OFF position.
2 Disconnect Passenger Air Bag Module Second
Stage Simulator.
3 Disconnect Air Bag Control Module C490.
4 Measure the resistance between the air bag
control module C490 pin 13, circuit 15S-JA31
(GN/WH) and pin 14, circuit 91S-JA31
(BK/WH) harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA31 (GN/WH) and
91S-JA31 (BK/WH). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.

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501-20B-82 Supplemental Restraint System 501-20B-82

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST AE: DTC B2294 ERROR VALUE 31: DRIVER SIDE AIR CURTAIN CIRCUIT
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AE1: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO BATTERY
OR IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Driver Side Air Curtain Module
Simulator.
3 Disconnect Air Bag Control Module C491.
4 Key in ON position.
5 Measure the voltage between:
- the air bag control module C491 pin 3, circuit
15S-JA50 (GN/OG) harness side and ground;
and
- the air bag control module C491 pin 4, circuit
91S- JA50 (BK/RD) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No

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501-20B-83 Supplemental Restraint System 501-20B-83

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
CONNECT the driver side air curtain mod-
ule simulator and the air bag control mod-
ule. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AF: DTC B2294 ERROR VALUE 30: DRIVER SIDE AIR CURTAIN CIRCUIT
SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AF1: CHECK THE DRIVER SIDE AIR CURTAIN CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AF2
→ No
GO to AF3
AF2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver side air curtain module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the side air curtain module cas-
ing.

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501-20B-84 Supplemental Restraint System 501-20B-84

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver side air curtain mod-
ule. REFER to Side Air Curtain Module in
this section. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.
AF3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Side Air Curtain Module
Simulator.
4 Measure the resistance between:
- the air bag control module C491 pin 3, circuit
15S-JA50 (GN/OG) harness side and ground;
and
- the air bag control module C491 pin 4, circuit
91S- JA50 (BK/RD) harness side and ground.

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501-20B-85 Supplemental Restraint System 501-20B-85

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AG: DTC B2294 ERROR VALUE 29: DRIVER SIDE AIR CURTAIN CIRCUIT OPEN
CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AG1: CHECK THE DRIVER SIDE AIR CURTAIN CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AG2
→ No
GO to AG3

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501-20B-86 Supplemental Restraint System 501-20B-86

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AG2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver side air curtain module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the side air curtain
module squib.

• Is the resistance between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver side air curtain mod-
ule. REFER to Side Air Curtain Module in
this section. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.
AG3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Side Air Curtain Simulator.

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501-20B-87 Supplemental Restraint System 501-20B-87

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C491 pin 3, circuit
15S-JA50 (GN/OG) and the driver side air
curtain module C597 pin 1, circuit 15S-JA50
(GN/OG) harness side; and
- the air bag control module C491 pin 4, circuit
91S-JA50 (BK/RD) and the driver side air cur-
tain module C597 pin 2, circuit 91S-JA50
(BK/RD) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA50 (GN/OG) and
91S-JA50 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AH: DTC B2294 ERROR VALUE 28: DRIVER SIDE AIR CURTAIN CIRCUIT LOW
RESISTANCE ON SQUIB
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AH1: CHECK THE DRIVER SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.

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501-20B-88 Supplemental Restraint System 501-20B-88

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the system prove out correctly?

→ Yes
GO to AH2
→ No
GO to AH3
AH2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
driver side air curtain module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the side air curtain
module squib.

• Is the resistance between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver side air curtain mod-
ule. REFER to Side Air Curtain Module in
this section. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.
AH3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR LOW RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C491 pin 3.
1 Key in OFF position.
2 Disconnect Driver Side Air Curtain Simulator.
3 Disconnect Air Bag Control Module C491.
4 Measure the resistance between the air bag
control module C491 pin 3, circuit 15S-JA50
(GN/OG) and pin 4, circuit 91S-JA50 (BK/RD)
harness side.
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501-20B-89 Supplemental Restraint System 501-20B-89

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA50 (GN/OG) and
91S-JA50 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AI: DTC B2294 ERROR VALUE 27: PASSENGER SIDE AIR CURTAIN CIRCUIT
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AI1: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Passenger Side Air Curtain Module
Simulator.
3 Disconnect Air Bag Control Module C491.
4 Key in ON position.
5 Measure the voltage between:
- the air bag control module C491 pin 5, circuit
15S-JA51 (GN/BU) harness side and ground;
and
- the air bag control module C491 pin 6, circuit
91S- JA51 (BK/BU) harness side and ground.

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501-20B-90 Supplemental Restraint System 501-20B-90

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
CONNECT the passenger side air curtain
module simulator and the air bag control
module. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AJ: DTC B2294 ERROR VALUE 26: PASSENGER SIDE AIR CURTAIN CIRCUIT
SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AJ1: CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AJ2
→ No
GO to AJ3

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501-20B-91 Supplemental Restraint System 501-20B-91

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AJ2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger side air curtain module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the side air curtain module cas-
ing.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger side air curtain
module. REFER to Side Air Curtain Module
in this section. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AJ3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Side Air Curtain Module
Simulator.

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501-20B-92 Supplemental Restraint System 501-20B-92

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C491 pin 5, circuit
15S-JA51 (GN/BU) harness side and ground ;
and
- the air bag control module C491 pin 6, circuit
91S- JA51 (BK/BU) harness side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AK: DTC B2294 ERROR VALUE 25: PASSENGER SIDE AIR CURTAIN CIRCUIT
OPEN CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AK1: CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?

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501-20B-93 Supplemental Restraint System 501-20B-93

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
GO to AK2
→ No
GO to AK3
AK2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger side air curtain module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the side air curtain
module squib.

• Is the resistance between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger side air curtain
module. REFER to Side Air Curtain Module
in this section. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AK3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Side Air Curtain Module
Simulator.

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501-20B-94 Supplemental Restraint System 501-20B-94

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the air bag control module C491 pin 5, circuit
15S-JA51 (GN/BU) and the passenger side
air curtain module C598 pin 1, circuit 15S-
JA51 (GN/BU) harness side; and
- the air bag control module C491 pin 6, circuit
91S-JA51 (BK/BU) and the passenger side
air curtain module C598 pin 2, circuit 91S-
JA51 (BK/BU) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA51 (GN/BU) and
91S-JA51 (BK/BU). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AL: DTC B2294 ERROR VALUE 24: PASSENGER SIDE AIR CURTAIN CIRCUIT
LOW RESISTANCE ON SQUIB
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AL1: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.

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501-20B-95 Supplemental Restraint System 501-20B-95

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the system prove out correctly?

→ Yes
GO to AL2
→ No
GO to AL3
AL2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
passenger side air curtain module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the side air curtain
module squib.

• Is the resistance between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger side air curtain
module. REFER to Side Air Curtain Module
in this section. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AL3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR LOW RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C491 pin 5.
1 Key in OFF position.
2 Disconnect Passenger Side Air Curtain Module
Simulator.
3 Disconnect Air Bag Control Module C491.

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501-20B-96 Supplemental Restraint System 501-20B-96

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between the air bag
control module C491 pin 5, circuit 15S-JA51
(GN/BU) and pin 6, circuit 91S-JA51 (BK/BU)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA51 (GN/BU) and
91S-JA51 (BK/BU). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AM: DTC B2295 ERROR VALUE 31: DRIVER SIDE AIR BAG CIRCUIT SHORT TO
BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AM1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes

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501-20B-97 Supplemental Restraint System 501-20B-97

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
GO to AM2
AM2: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Key in ON position.
4 Measure the voltage between:
- the air bag control C491 pin 1, circuit 15S-
JA37 (GN/BK) harness side and ground; and
- the air bag control module C491 pin 2, circuit
91S-JA37 (BK/GN) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
PINPOINT TEST AN: DTC B2295 ERROR VALUE 30: DRIVER SIDE AIR BAG CIRCUIT SHORT TO
GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-98 Supplemental Restraint System 501-20B-98

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AN1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AN2
→ No
GO to AN5
AN2: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
1 Key in OFF position.
2 Measure the resistance between:
- the driver side air bag module underseat
connector C60b pin 1, circuit 15S-JA37
(GN/BK) component side and ground; and
- the driver side air bag module underseat con-
nector C60b pin 2, circuit 91S-JA37 (BK/GN)
component side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
GO to AN3
AN3: CHECK THE DRIVER SIDE AIR BAG WIRING SUB-HARNESS FOR HIGH RESISTANCE
1 Disassemble the front seat backrest to access
the side air bag module electrical connector.
REFER to Side Air Bag Module in this section.
2 Disconnect Driver Side Air Bag Module C217.

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501-20B-99 Supplemental Restraint System 501-20B-99

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between:
- the driver side air bag module underseat
connector C60b pin 1, circuit 15S-JA37
(GN/BK) component side and the seat frame;
and
- the driver side air bag module underseat con-
nector C60b pin 2, circuit 91S-JA37 (BK/GN)
component side and the seat frame.

• Are the resistances greater than 10,000 ohms?

→ Yes
GO to AN4
→ No
REPAIR circuits 15S-JA37 (GN/BK) and
91S-JA37 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AN4: CHECK THE DRIVER SIDE AIR BAG MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver side air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the side air bag module casing.

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501-20B-100 Supplemental Restraint System 501-20B-100

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver side air bag module.
REFER to Side Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AN5: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the air bag control C491 pin 1, circuit 15S-
JA37 (GN/BK) harness side and ground; and
- the air bag control module C491 pin 2, circuit
91S-JA37 (BK/GN) harness side and ground.

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501-20B-101 Supplemental Restraint System 501-20B-101

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AO: DTC B2295 ERROR VALUE 29: DRIVER SIDE AIR BAG CIRCUIT OPEN
CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AO1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AO2
→ No
GO to AO4
AO2: CHECK THE DRIVER SIDE AIR BAG WIRING SUB-HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
1 Key in OFF position.
2 Disassemble the front seat backrest to access
the side air bag module electrical connector.
REFER to Side Air Bag Module in this section.
3 Disconnect Driver Side Air Bag Module C217.

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501-20B-102 Supplemental Restraint System 501-20B-102

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
4 Measure the resistance between:
- the driver side air bag module underseat
connector C60b pin 1, circuit 15S-JA37
(GN/BK) and the driver air bag module C217
pin 1, circuit 15S-JA37 (GN/BK) harness side;
and
- the driver side air bag module underseat con-
nector C60b pin 2, circuit 91S-JA37 (BK/GN)
and the driver air bag module C217 pin 2, cir-
cuit 91S-JA37 (BK/GN) harness side.

• Are the resistances less than 5 ohms?

→ Yes
GO to AO3
→ No
REPAIR circuits 15S-JA37 (GN/BK) and
91S-JA37 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AO3: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver side air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.

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501-20B-103 Supplemental Restraint System 501-20B-103

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver side air bag module.
REFER to Side Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AO4: CHECK THE DRIVER SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR HIGH
RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the air bag control module C491 pin 1, circuit
15S-JA37 (GN/BK) and the driver side air bag
module underseat connector C60 pin 5,
circuit 15S-JA37 (GN/BK) harness side; and
- the air bag control module C491 pin 2, circuit
91S-JA37 (BK/GN) and the driver side air bag
module underseat connector C60 pin 6, cir-
cuit 91S-JA37 (BK/GN) harness side.

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501-20B-104 Supplemental Restraint System 501-20B-104

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA37 (GN/BK) and
91S-JA37 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AP: DTC B2295 ERROR VALUE 28: DRIVER SIDE AIR BAG CIRCUIT LOW
RESISTANCE ON SQUIB
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AP1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AP2
→ No
GO to AP4
AP2: CHECK THE DRIVER SIDE AIR BAG WIRING SUB-HARNESS FOR LOW RESISTANCE
1 Key in OFF position.

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501-20B-105 Supplemental Restraint System 501-20B-105

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Disassemble the front seat backrest to access
the side air bag module electrical connector.
REFER to Side Air Bag Module in this section.
3 Disconnect Air Bag Control Module C491.
4 Disconnect Driver Side Air Bag Module C217.
5 Measure the resistance between:
- the driver side air bag module underseat con-
nector C60b pin 1, circuit 15S-JA37 (GN/BK)
and pin 2, circuit 91S-JA37 (BK/GN) harness
side.

• Is the resistance greater than 10,000 ohms?

→ Yes
GO to AP3
→ No
REPAIR circuits 15S-JA37 (GN/BK) and
91S-JA37 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AP3: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
driver side air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.

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501-20B-106 Supplemental Restraint System 501-20B-106

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new driver side air bag module.
REFER to Side Air Bag Module in this sec-
tion. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AP4: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C491 pin 1.
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between the air bag
control module C491 pin 1, circuit 15S-JA37
(GN/BK) and pin 2, circuit 91S-JA37 (BK/GN)
harness side.

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501-20B-107 Supplemental Restraint System 501-20B-107

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA37 (GN/BK) and
91S-JA37 (BK/GN). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AQ: DTC B2295 ERROR VALUE 27: PASSENGER SIDE AIR BAG CIRCUIT
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AQ1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
GO to AQ2
AQ2: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Key in ON position.
4 Measure the voltage between:
- the air bag control C491 pin 21, circuit 15S-
JA38 (GN/OG) harness side and ground; and
- the air bag control module C491 pin 22, cir-
cuit 91S-JA38 (BK/RD) harness side and
ground.

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501-20B-108 Supplemental Restraint System 501-20B-108

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
PINPOINT TEST AR: DTC B2295 ERROR VALUE 26: PASSENGER SIDE AIR BAG CIRCUIT
SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AR1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AR2
→ No
GO to AR5
AR2: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
1 Key in OFF position.
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501-20B-109 Supplemental Restraint System 501-20B-109

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the resistance between:
- the passenger side air bag module underseat
connector C61b pin 1, circuit 15S-JA38
(GN/OG) component side and ground; and
- the passenger side air bag module underseat
connector C61b pin 2, circuit 91S-JA38
(BK/RD) component side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
GO to AR3
AR3: CHECK THE PASSENGER SIDE AIR BAG WIRING SUB-HARNESS FOR HIGH
RESISTANCE
1 Disassemble the front seat backrest to access
the side air bag module electrical connector.
REFER to Side Air Bag Module in this section.
2 Disconnect Passenger Side Air Bag Module
C218.
3 Measure the resistance between:
- the passenger side air bag module underseat
connector C61b pin 1, circuit 15S-JA38
(GN/OG) component side and the seat frame;
and
- the passenger side air bag module underseat
connector C61b pin 2, circuit 91S-JA38
(BK/RD) component side and the seat frame.

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501-20B-110 Supplemental Restraint System 501-20B-110

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
GO to AR4
→ No
REPAIR circuits 15S-JA38 (GN/OG) and
91S-JA38 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AR4: CHECK THE PASSENGER SIDE AIR BAG MODULE

WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger side air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance between each of the
terminals and the side air bag module casing.

• Are the resistances greater than 10,000 ohms?

→ Yes

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501-20B-111 Supplemental Restraint System 501-20B-111

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger side air bag
module. REFER to Side Air Bag Module in
this section. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.
AR5: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between:
- the air bag control C491 pin 21, circuit 15S-
JA38 (GN/OG) harness side and ground; and
- the air bag control module C491 pin 22, cir-
cuit 91S-JA38 (BK/RD) harness side and
ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.

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501-20B-112 Supplemental Restraint System 501-20B-112

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST AS: DTC B2295 ERROR VALUE 25: PASSENGER SIDE AIR BAG CIRCUIT OPEN
CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AS1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AS2
→ No
GO to AS4
AS2: CHECK THE PASSENGER SIDE AIR BAG WIRING SUB-HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
1 Key in OFF position.
2 Disassemble the front seat backrest to access
the side air bag module electrical connector.
REFER to Side Air Bag Module in this section.
3 Disconnect Passenger Side Air Bag Module
C218.
4 Measure the resistance between:
- the passenger side air bag module underseat
connector C61b pin 1, circuit 15S-JA38
(GN/OG) and the passenger air bag module
C218 pin 1, circuit 15S-JA38 (GN/OG)
harness side; and
- the passenger side air bag module underseat
connector C61b pin 2, circuit 91S-JA38
(BK/RD) and the passenger air bag module
C218 pin 2, circuit 91S-JA38 (BK/RD) har-
ness side.

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501-20B-113 Supplemental Restraint System 501-20B-113

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
GO to AS3
→ No
REPAIR circuits 15S-JA38 (GN/OG) and
91S-JA38 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AS3: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger side air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.

• Is the resistance between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger side air bag
module. REFER to Side Air Bag Module in
this section. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.

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501-20B-114 Supplemental Restraint System 501-20B-114

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AS4: CHECK THE PASSENGER SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between:
- the air bag control module C491 pin 21,
circuit 15S-JA38 (GN/OG) and the passenger
side air bag module underseat connector C61
pin 5, circuit 15S-JA38 (GN/OG) harness
side; and
- the air bag control module C491 pin 22, cir-
cuit 91S-JA38 (BK/RD) and the passenger
side air bag module underseat connector C61
pin 6, circuit 91S-JA38 (BK/RD) harness side.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA38 (GN/OG) and
91S-JA38 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AT: DTC B2295 ERROR VALUE 24: PASSENGER SIDE AIR BAG CIRCUIT LOW
RESISTANCE ON SQUIB
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-115 Supplemental Restraint System 501-20B-115

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AT1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
GO to AT2
→ No
GO to AT4
AT2: CHECK THE PASSENGER SIDE AIR BAG WIRING SUB-HARNESS FOR LOW RESISTANCE
1 Key in OFF position.
2 Disassemble the front seat backrest to access
the side air bag module electrical connector.
REFER to Side Air Bag Module in this section.
3 Disconnect Air Bag Control Module C491.
4 Disconnect Passenger Side Air Bag Module
C218.
5 Measure the resistance between:
- the passenger side air bag module underseat
connector C61b pin 1, circuit 15S-JA38
(GN/OG) and pin 2, circuit 91S-JA38 (BK/RD)
harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
GO to AT3
→ No
REPAIR circuits 15S-JA38 (GN/OG) and
91S-JA38 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.

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501-20B-116 Supplemental Restraint System 501-20B-116

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AT3: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE

WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment Lead to the
passenger side air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.

• Is the resistance between 2 and 3 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new passenger side air bag
module. REFER to Side Air Bag Module in
this section. REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System
(SRS) in this section.
AT4: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
NOTE: Using a suitable non-conducting tool, disable the shorting bar on C491 pin 21.
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between the air bag
control module C491 pin 21, circuit 15S-JA38
(GN/OG) and pin 22, circuit 91S-JA38 (BK/RD)
harness side.

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501-20B-117 Supplemental Restraint System 501-20B-117

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is the resistance greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 15S-JA38 (GN-OG) and
91S-JA38 (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST AU: DTC B2296 ERROR VALUE 31: DRIVER SIDE IMPACT SENSOR
COMMUNICATIONS FAULT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AU1: CHECK THE DRIVER SIDE IMPACT SENSOR CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Driver Side Impact Sensor C453.
3 Disconnect Air Bag Control Module C491.
4 Measure the resistance between:
- the air bag control module C491 pin 27,
circuit 8-JA39 (WH) and the driver side
impact sensor C453 pin 1, circuit 8-JA39
(WH) harness side; and
- the air bag control module C491 pin 28, cir-
cuit 9-JA39 (BN) and the driver side impact
sensor C453 pin 2, circuit 9-JA39 (BN) har-
ness side.

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501-20B-118 Supplemental Restraint System 501-20B-118

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
GO to AU2
→ No
REPAIR circuits 8-JA39 (WH) and 9-JA39
(BN). REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AU2: CHECK THE DRIVER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO BATTERY
1 Measure the voltage between:
- the air bag control module C491 pin 27,
circuit 8-JA39 (WH) harness side and ground;
and
- the air bag control module C491 pin 28, cir-
cuit 9-JA39 (BN) harness side and ground.

• Is any voltage present?

→ Yes

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501-20B-119 Supplemental Restraint System 501-20B-119

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to AU3
AU3: CHECK THE DRIVER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO GROUND
1 Measure the resistance between:
- the air bag control module C491 pin 27,
circuit 8-JA39 (WH) harness side and ground;
and
- the air bag control module C491 pin 28, cir-
cuit 9-JA39 (BN) harness side and ground.

• Are the resistance greater than 10,000 Ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AV: DTC B2296 ERROR VALUE 29: PASSENGER SIDE IMPACT SENSOR
COMMUNICATIONS FAULT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.

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501-20B-120 Supplemental Restraint System 501-20B-120

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
AV1: CHECK THE PASSENGER SIDE IMPACT SENSOR CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Passenger Side Impact Sensor
C495.
3 Disconnect Air Bag Control Module C491.
4 Measure the resistance between:
- the air bag control module C491 pin 29,
circuit 8-JA40 (WH/VT) and the passenger
side impact sensor C495 pin 1, circuit 8-JA40
(WH/VT) harness side; and
- the air bag control module C491 pin 30, cir-
cuit 9-JA40 (BN/WH) and the passenger side
impact sensor C495 pin 2, circuit 9-JA40
(BN/WH) harness side.

• Are the resistances less than 5 ohms?

→ Yes
GO to AV2
→ No
REPAIR circuits 8-JA40 (WH/VT) and 9-
JA40 (BN/WH). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AV2: CHECK THE PASSENGER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO BATTERY
1 Key in ON position.
2 Measure the voltage between:
- the air bag control module C491 pin 29,
circuit 8-JA40 (WH/VT) harness side and
ground; and
- the air bag control module C491 pin 30, cir-
cuit 9-JA40 (BN/WH) harness side and
ground.

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501-20B-121 Supplemental Restraint System 501-20B-121

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to AV3
AV3: CHECK THE PASSENGER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO GROUND
1 Key in OFF position.
2 Measure the resistance between:
- the air bag control module C491 pin 29,
circuit 8-JA40 (WH/VT) harness side and
ground; and
- the air bag control module C491 pin 30, cir-
cuit 9-JA40 (BN/WH) harness side and
ground.

• Are the resistance greater than 10,000 Ohms?

→ Yes

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501-20B-122 Supplemental Restraint System 501-20B-122

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AW: DTC B2296 ERROR VALUE 19: CRASH SENSOR COMMUNICATIONS
FAULT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AW1: CHECK THE CRASH SENSOR CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Disconnect Crash Sensor C496.
3 Disconnect Air Bag Control Module C491.
4 Measure the resistance between:
- the air bag control module C491 pin 19,
circuit 8-JA49 (WH) and the crash sensor
C496 pin 1, circuit 8-JA49 (WH) harness side;
and
- the air bag control module C491 pin 20, cir-
cuit 9-JA49 (BN) and the crash sensor C496
pin 2, circuit 9-JA49 (BN) harness side.

• Are the resistances less than 5 ohms?

→ Yes
GO to AW2

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501-20B-123 Supplemental Restraint System 501-20B-123

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ No
REPAIR circuits 8-JA49 (WH) and 9-JA49
(BN). REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
AW2: CHECK THE CRASH SENSOR FOR A SHORT CIRCUIT TO BATTERY
1 Key in ON position.
2 Measure the voltage between:
- the air bag control module C491 pin 19,
circuit 8-JA49 (WH) harness side and ground;
and
- the air bag control module C491 pin 20, cir-
cuit 9-JA49 (BN) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to AW3
AW3: CHECK THE CRASH SENSOR FOR A SHORT CIRCUIT TO GROUND
1 Key in OFF position.
2 Measure the resistance between:
- the air bag control module C491 pin 19,
circuit 8-JA49 (WH) harness side and ground;
and
- the air bag control module C491 pin 20, cir-
cuit 9-JA49 (BN) harness side and ground.

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501-20B-124 Supplemental Restraint System 501-20B-124

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistance greater than 10,000 Ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
PINPOINT TEST AX: DTC B2434: DRIVER SAFETY BELT BUCKLE SWITCH SHORT TO GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AX1: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes

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501-20B-125 Supplemental Restraint System 501-20B-125

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new driver safety belt buckle
and pretensioner. REFER to Section 501-
20A / 501-20B. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
→ No
GO to AX2
AX2: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO
GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the driver safety belt buckle switch C60 pin
13, circuit 91-GE52A (BK/RD) and pin 14,
circuit 91S-GE52A (BK/RD) harness side.
- the driver safety belt buckle switch C60 pin
14, circuit 91S-GE52A (BK/RD) harness side
and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuit 91-GE52A (BK/RD) and
91S-GE52A (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.

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501-20B-126 Supplemental Restraint System 501-20B-126

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST AY: DTC B2435: DRIVER SAFETY BELT BUCKLE SWITCH RESISTANCE OUT
OF RANGE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AY1: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
INSTALL a new driver safety belt buckle
and pretensioner. REFER to Section 501-
20A / 501-20B. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
→ No
GO to AY2
AY2: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR LOW RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the driver safety belt buckle switch C60 pin
13, circuit 91-GE52A (BK/RD) and pin 14,
circuit 91S-GE52A (BK/RD) harness side;
and
- the driver safety belt buckle switch C60 pin
14, circuit 91S-GE52A (BK/RD) harness side
and ground.

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501-20B-127 Supplemental Restraint System 501-20B-127

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
GO to AY3
→ No
REPAIR circuit 91-GE52A (BK/RD) and
91S-GE52A (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
AY3: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR HIGH RESISTANCE
1 Key in OFF position.
2 Disconnect Driver Underseat Air Bag Simula-
tor.
3 Measure the resistance between:
- the driver safety belt buckle switch C60 pin
14, circuit 91S-GE52A (BK/RD) and the air
bag control module C491 pin 25, circuit 91S-
GE52A (BK/RD) harness side; and
- the driver safety belt buckle switch C60 pin
13, circuit 91-GE52A (BK/RD) harness side
and ground.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
INSTALL a new air bag wiring harness.
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.

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501-20B-128 Supplemental Restraint System 501-20B-128

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST AZ: DTC B2438: PASSENGER SAFETY BELT BUCKLE SWITCH SHORT TO
GROUND
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
AZ1: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
INSTALL a new passenger safety belt
buckle and pretensioner. REFER to Section
501-20A / 501-20B. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
→ No
GO to AZ2
AZ2: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO
GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between:
- the passenger safety belt buckle switch C61
pin 13, circuit 91-GE52B (BK/RD) and pin 14,
circuit 91S-GE52B (BK/RD) harness side;
and
- the passenger safety belt buckle switch C60
pin 14, circuit 91S-GE52B (BK/RD) harness
side and ground.

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501-20B-129 Supplemental Restraint System 501-20B-129

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances greater than 10,000 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 91-GE52B (BK/RD) and
91S-GE52B (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST BA: DTC B2439: PASSENGER SAFETY BELT BUCKLE SWITCH RESISTANCE
OUT OF RANGE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
BA1: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
INSTALL a new passenger safety belt
buckle and pretensioner. REFER to Section
501-20A / 501-20B. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem.
→ No

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501-20B-130 Supplemental Restraint System 501-20B-130

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to BA2
BA2: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR LOW
RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Passenger Underseat Air Bag
Simulator.
4 Measure the resistance between:
- the passenger safety belt buckle switch C61
pin 13, circuit 91-GE52B (BK/RD) and pin 14,
circuit 91S-GE52B (BK/RD) harness side;
and
- the passenger safety belt buckle switch C61
pin 14, circuit 91S-GE52B (BK/RD) harness
side and ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
GO to BA3
→ No
REPAIR circuits 91-GE52B (BK/RD) and
91S-GE52B (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
BA3: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR HIGH
RESISTANCE
1 Disconnect Passenger Underseat Air Bag
Simulator.
2 Measure the resistance between:
- the passenger safety belt buckle switch C61
pin 14, circuit 91S-GE52B (BK/RD) and the
air bag control module C491 pin 26, circuit
91S-GE52B (BK/RD) harness side; and
- the passenger safety belt buckle switch C61
pin 13, circuit 91-GE52B (BK/RD) harness
side and ground.

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501-20B-131 Supplemental Restraint System 501-20B-131

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 91S-GE52B (BK/RD) and
91-GE52B (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST BB: DTC B2691: DRIVER SAFETY BELT BUCKLE SWITCH OPEN CIRCUIT OR
SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS
BB1: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow
this instruction may result in personal injury.
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes

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501-20B-132 Supplemental Restraint System 501-20B-132

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new driver safety belt buckle
and pretensioner. REFER to Section 501-
20A / 501-20B. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
→ No
GO to BB2
BB2: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO
BATTERY
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Key in ON position.
4 Measure the voltage between the air bag con-
trol module C491 pin 25, circuit 91S-GE52A
(BK/RD) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to BB3
BB3: CHECK THE DRIVER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR AN OPEN CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Underseat Air Bag Simula-
tor.

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501-20B-133 Supplemental Restraint System 501-20B-133

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between:
- the driver safety belt buckle switch C60 pin
14, circuit 91S-GE52A (BK/RD) and the air
bag control module C491 pin 25, circuit 91S-
GE52A (BK/RD) harness side; and
- the driver safety belt buckle switch C60 pin
13, circuit 91-GE52A (BK/RD) harness side
and ground.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 91S-GE52A (BK/RD) and
91-GE52A (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST BC: DTC B2692: PASSENGER SAFETY BELT BUCKLE SWITCH OPEN CIRCUIT
OR SHORT TO BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS
BC1: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow
this instruction may result in personal injury.
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.

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501-20B-134 Supplemental Restraint System 501-20B-134

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Does the system prove out correctly?

→ Yes
INSTALL a new passenger safety belt
buckle and pretensioner. REFER to Section
501-20A / 501-20B. REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
→ No
GO to BC2
BC2: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR A SHORT TO
BATTERY
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Key in ON position.
4 Measure the voltage between the air bag con-
trol module C491 pin 26, circuit 91S-GE52B
(BK/RD) harness side and ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to BC3
BC3: CHECK THE PASSENGER SAFETY BELT BUCKLE SWITCH CIRCUIT FOR AN OPEN
CIRCUIT
1 Key in OFF position.
2 Disconnect Passenger Underseat Air Bag
Simulator.

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501-20B-135 Supplemental Restraint System 501-20B-135

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
3 Measure the resistance between:
- the passenger safety belt buckle switch C61
pin 14, circuit 91S-GE52B (BK/RD) and the
air bag control module C491 pin 26, circuit
91S-GE52B (BK/RD) harness side; and
- the passenger safety belt buckle switch C61
pin 13, circuit 91-GE52B (BK/RD) harness
side and ground.

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 91S-GE52B (BK/RD) and
91-GE52B (BK/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST BD: DTC C1947: SEAT POSITION SENSOR SHORT TO GROUND OR BATTERY
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
BD1: CHECK THE SEAT POSITION SENSOR CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?

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501-20B-136 Supplemental Restraint System 501-20B-136

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
INSTALL a new seat position sensor.
REFER to Section 501-10. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
GO to BD2
BD2: CHECK THE SEAT POSITION SENSOR FOR A SHORT TO GROUND
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the air bag control module C491 pin 23,
circuit 8-JA53 (WH/RD) harness side and
ground; and
- the air bag control module C491 pin 24, cir-
cuit 9-JA53 (BN/RD) harness side and
ground.

• Are the resistances greater than 10,000 ohms?

→ Yes
GO to BD3
→ No
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
BD3: CHECK THE SEAT POSITION SENSOR FOR A SHORT TO BATTERY
1 Key in ON position.

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501-20B-137 Supplemental Restraint System 501-20B-137

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
2 Measure the voltage between:
- the air bag control module C491 pin 23,
circuit 8-JA53 (WH/RD) harness side and
ground; and
- the air bag control module C491 pin 24, cir-
cuit 9-JA53 (BN/RD) harness side and
ground.

• Is any voltage present

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
PINPOINT TEST BE: DTC C1948: SEAT POSITION SENSOR RESISTANCE OUT OF RANGE
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
BE1: CHECK THE SEAT POSITION SENSOR CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?

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501-20B-138 Supplemental Restraint System 501-20B-138

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
→ Yes
INSTALL a new seat position sensor.
REFER to Section 501-10. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No
GO to BE2
BE2: CHECK THE SEAT POSITION SENSOR CIRCUIT FOR LOW RESISTANCE
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Disconnect Driver Underseat Air Bag Simula-
tor.
4 Measure the resistance between:
- the air bag control module C491 pin 23, cir-
cuit 8-JA53 (WH/RD) and pin 24, circuit 9-
JA53 (BN/RD) harness side.

• Is the resistance greater than 10,000 ohms?

→ Yes
GO to BE3
→ No
REPAIR circuits 8-JA53 (WH/RD) and 9-
JA53 (BN/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
BE3: CHECK THE SEAT POSITION SENSOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
- the air bag control module C491 pin 23,
circuit 8-JA53 (WH/RD) and the seat position
sensor C60 pin 2, circuit 8-JA53 (WH/RD)
harness side; and
- the air bag control module C491 pin 24, cir-
cuit 9-JA53 (BN/RD) and the seat position
sensor C60 pin 1, circuit 9-JA53 (BN/RD)
harness side.

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501-20B-139 Supplemental Restraint System 501-20B-139

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 8-JA53 (WH/RD) and 9-
JA53 (BN/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST BF: DTC C1981: SEAT POSITION SENSOR OPEN CIRCUIT
CONDITIONS DETAILS/RESULTS/ACTIONS

WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury.
BF1: CHECK THE SEAT POSITION SENSOR CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Key in ON position.
3 Carry out the self-test with the simulators in-
stalled.
• Does the system prove out correctly?
→ Yes
INSTALL a new seat position sensor.
REFER to Section 501-10. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
→ No

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501-20B-140 Supplemental Restraint System 501-20B-140

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
GO to BF2
BF2: CHECK THE SEAT POSITION SENSOR CIRCUIT FOR A SHORT TO BATTERY
1 Key in OFF position.
2 Disconnect Air Bag Control Module C491.
3 Key in ON position.
4 Measure the voltage between:
- the air bag control module C491 pin 23,
circuit 8-JA53 (WH/RD) harness side and
ground; and
- the air bag control module C491 pin 24, cir-
cuit 9-JA53 (BN/RD) harness side and
ground.

• Is any voltage present?

→ Yes
REPAIR the air bag wiring harness. For ad-
ditional information, refer to the Wiring Dia-
grams. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
GO to BF3
BF3: CHECK THE SEAT POSITION SENSOR CIRCUIT FOR AN OPEN CIRCUIT
1 Key in OFF position.
2 Disconnect Driver Underseat Air Bag Simula-
tor.
3 Measure the resistance between:
- the air bag control module C491 pin 23,
circuit 8-JA53 (WH/RD) and the seat position
sensor C60 pin 2, circuit 8-JA53 (WH/RD)
harness side; and
- the air bag control module C491 pin 24, cir-
cuit 9-JA53 (BN/RD) and the seat position
sensor C60 pin 1, circuit 9-JA53 (BN/RD)
harness side.

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501-20B-141 Supplemental Restraint System 501-20B-141

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS

• Are the resistances less than 5 ohms?

→ Yes
REPEAT the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
→ No
REPAIR circuits 8-JA53 (WH/RD) and 9-
JA53 (BN/RD). REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the sys-
tem. REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
PINPOINT TEST BG: AIR BAG CONTROL MODULE DISCONNECTED OR INOPERATIVE
CONDITIONS DETAILS/RESULTS/ACTIONS
BG1: CHECK THE AIR BAG CONTROL MODULE ELECTRICAL CONNECTORS
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
2 Check the air bag control module electrical
connectors.
• Are the air bag control module electrical con-
nectors fully connected with the red locking tabs
engaged?
→ Yes
GO to BG2
→ No
CONNECT the air bag control module elec-
trical connectors and engage the red locking
tabs. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.

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501-20B-142 Supplemental Restraint System 501-20B-142

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
BG2: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT
1 Disconnect Air Bag Control Module C490.
2 Key in ON position.
3 Measure the voltage between the air bag con-
trol module C490 pin 12, circuit 15-JA10
(GN/OG) harness side and ground.

• Is the voltage between 9 and 16 volts?

→ Yes
GO to BG3
→ No
REPAIR circuit 15-JA10 (GN/OG). REPEAT
the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.
BG3: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT
1 Key in OFF position.
2 Measure the resistance between the air bag
control module C490 pin 16, circuit 91-JA10
(BK/RD) harness side and ground.

• Is the resistance less than 5 ohms?

→ Yes

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501-20B-143 Supplemental Restraint System 501-20B-143

DIAGNOSIS AND TESTING (Continued)

CONDITIONS DETAILS/RESULTS/ACTIONS
INSTALL a new air bag control module.
REFER to Air Bag Control Module in this
section. REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
→ No
REPAIR circuit 91-JA10 (BK/RD). REPEAT
the self-test, CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec-
tion.

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501-20B-144 Supplemental Restraint System 501-20B-144

GENERAL PROCEDURES

Deployed Air Bag Disposal

GENERAL PROCEDURES

WARNING: After deployment, the air bag

module surface may contain deposits of
sodium hydroxide, a product of the gas
generate combustion, that is irritating to
the skin. Use protective gloves when
handling any deployed air bag module.
Failure to follow this instruction may
result in personal injury.
1. Remove the deployed air bag module(s).
For additional information, refer to the
relevant procedure in this section.
2. Seal the deployed air bag module(s) in the
packaging from the new air bag module(s)
or a suitable polythene bag, and then
dispose of in accordance with local
contaminated waste regulations.

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501-20B-145 Supplemental Restraint System 501-20B-145

GENERAL PROCEDURES

Unserviceable Air Bag Disposal

1. WARNING: To minimise the possibility 3. WARNING: Under no circumstances is

of injury in the event of premature an unserviceable air bag module(s) to
deployment, always carry a live air be returned through the local mailing
bag module with the bag and trim system. Failure to follow this
cover pointed away from the body. instruction may result in personal
Failure to follow this instruction may injury.
result in personal injury.
Seal the unserviceable air bag module(s)
WARNING: To prevent premature in the packaging from the new air bag
deployment, live air bag modules must module(s) and return to the Exchange Plan
only be placed on work benches which Center, as appointed through the local
have been ground bonded. Failure to National Sales Company.
follow this instruction may result in
personal injury.
NOTE: All unserviceable air bag modules have
been placed on the Mandatory Return List. All
discolored or damaged air bag modules should
be treated the same as any unserviceable live air
bag module being returned.
Remove the unserviceable air bag module.
For additional information, refer to the
relevant procedure in this section.
NOTE: A prepaid, return postcard is provided
with the new air bag module. The new air bag
module serial number and the vehicle
identification number (VIN) must be recorded on
the air bag module verification card.
2. Before installing the air bag module, re-
cord the necessary information. Return the
air bag module verification card to Ford
Motor Company (driver air bag module
verification card shown).

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501-20B-146 Supplemental Restraint System 501-20B-146

GENERAL PROCEDURES

Scrapped Vehicle Undeployed Air Bag Disposal

Two stage air bag modules
4. CAUTION: Do not connect both test
Special Tool(s) leads to the adapter. Both air bag
Test and Deployment Lead, module inflators must be deployed
Air Bag/Pyrotechnic Safety separately.
Belt Connect two test leads to the air bag mod-
418-S055 (40-007A) ule and the other end of one of the test
leads to the adapter (driver air bag module
shown).

General Equipment
12 volt battery
All vehicles
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work All air bag modules
benches which have been ground 5. CAUTION: To protect the test lead
bonded. Failure to follow this instruction electrical connector(s) from damage
may result in personal injury. during deployment, raise the air bag
1. Disconnect the battery ground cable. For module off the ground on two wooden
additional information, refer to Section blocks.
414-01.
Place the air bag module inside a suitable
2. Remove the air bag module(s) to be
rigid wire cage with the air bag module
deployed. For additional information, refer
cover uppermost.
to the relevant procedure(s) in this section.
Single stage air bag modules
3. Connect the test lead to the air bag module
and the adapter (driver air bag module
shown).

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501-20B-147 Supplemental Restraint System 501-20B-147

GENERAL PROCEDURES (Continued)

6. Connect the deployment lead to the 8. CAUTION: The air bag module should
adapter. not be handled immediately following
deployment as the air bag module will
be very hot.
CAUTION: After deployment, the air bag
module surface may contain deposits of
sodium hydroxide, a product of the gas
generate combustion, that is irritating to
the skin. Use protective gloves when
handling any deployed air bag module.
Depress both switches to deploy the air
bag.

7. WARNING: Before proceeding make

sure that all personnel in the vicinity
are aware that a loud noise (bang) is
about to occur. Do not let anybody
approach closer than six meters.
Failure to follow this instruction may
result in personal injury.
Move as far away as possible from the air
bag module and connect the deployment
lead to the battery.

Two stage air bag modules

9. Connect the second test lead to the
adapter.

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501-20B-148 Supplemental Restraint System 501-20B-148

GENERAL PROCEDURES (Continued)

10. WARNING: Before proceeding make

sure that all personnel in the vicinity
are aware that a loud noise (bang) is
about to occur. Do not let anybody
approach closer than six meters.
Failure to follow this instruction may
result in personal injury.
CAUTION: The air bag module should not
be handled immediately following
deployment as the air bag module will be
very hot.
CAUTION: After deployment, the air bag
module surface may contain deposits of
sodium hydroxide, a product of the gas
generate combustion, that is irritating to
the skin. Use protective gloves when
handling any deployed air bag module.
Depress both switches to deploy the air
bag.

All air bag modules

11. Deployed air bag module(s) should be
sealed in a suitable bag and then
disposed of in accordance with local
contaminated waste regulations.

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501-20B-149 Supplemental Restraint System 501-20B-149

GENERAL PROCEDURES

Safety Belt Pretensioner Disposal

2. NOTE: Certain vehicles require the removal of
the front seat to access the safety belt
pretensioner electrical connector.
Special Tool(s)
Remove the front seat (if necessary).
Test and Deployment Lead, For additional information, refer to Section
Air Bag/Pyrotechnic Safety 501-10.
Belt 3. Detach the safety belt pretensioner
418-S055 (40-007A) electrical connector from the front seat.
4. Install the front seat (if necessary). For
additional information, refer to Section
General Equipment 501-10.

12v Battery 5. CAUTION: Make sure the seat

mounting bolts are installed.
Connect the deployment lead to the safety
Deploy belt pretensioner electrical connector.

WARNING: To avoid accidental

deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: Before deploying the air bag
module or safety belt pretensioner, make 6. Connect the deployment lead to the
sure that all personnel in the vicinity are adapter lead.
aware that a loud noise (bang) is about
to occur. Do not let anybody approach
closer than six meters. Failure to follow
this instruction may result in personal
injury.
WARNING: The air bag module or the
safety belt pretensioner should not be
handled immediately following
deployment as the air bag module or
safety belt pretensioner will be very hot.
Failure to follow this instruction may
result in personal injury.
1. Disconnect the battery ground cable.
For additional information, refer to Section
414-01.

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501-20B-150 Supplemental Restraint System 501-20B-150

GENERAL PROCEDURES (Continued)

7. Move as far away as possible from the ve- 11. WARNING: Under no circumstances
hicle and connect the deployment lead to is an unserviceable air bag module or
the battery. safety belt buckle pretensioner to be
returned through the local mailing
system. Failure to follow this
instruction may result in personal
injury.
NOTE: All unserviceable air bag modules have
been placed on the Mandatory Return List. All
discolored or damaged air bag modules should
be treated the same as any unserviceable live air
bag module being returned.
If an air bag module or safety belt buckle
pretensioner fails to deploy, seal the
unserviceable air bag module or safety
belt buckle pretensioner in suitable
packaging and return to the Exchange
8. Depress both switches to deploy the Plan Center, as appointed through the
safety belt pretensioner. local National Sales Company.

9. Remove the safety belt buckle and

pretensioner. For additional
information, refer to Safety Belt Buckle
and Pretensioner in this section.
10. Deployed air bag module(s) and safety
belt pretensioners should be sealed in
suitable bags and then disposed of in
accordance with local contaminated
waste regulations.

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501-20B-151 Supplemental Restraint System 501-20B-151

REMOVAL AND INSTALLATION

Side Impact Sensor (40 699 0)

REMOVAL AND INSTALLATION

Removal 3. NOTE: To aid installation, set the safety belt

shoulder height adjuster to its lowest position.
WARNING: To avoid accidental
deployment, the air bag control module Detach the B-pillar upper trim panel from
backup power supply must be depleted. the B-pillar and position to one side.
Wait at least one minute after 1. Detach the locating tangs from the B-pillar
disconnecting the battery ground lower trim panel.
cable(s) before commencing any repair 2. Remove the screw cover.
or adjustment to the supplemental
restraint system (SRS), or any 3. Remove the retaining screw.
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this 4. Remove the B-pillar lower trim panel.
instruction may result in personal injury. 1. Remove the retaining screws.
1. Disconnect the battery ground cable. For 2. Detach the retaining clips.
additional information, refer to Section
414-01.
2. Detach the weatherstrips from the B-pillar.

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501-20B-152 Supplemental Restraint System 501-20B-152

REMOVAL AND INSTALLATION (Continued)

5. Remove the cowl side trim panel. Installation
1. Remove the retaining screws.
WARNING: Make sure the side impact
2. Detach the retaining clips.
sensor locating tangs are correctly
located into the B-pillar. Failure to follow
this instruction may result in personal
injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
CAUTION: Make sure the safety belt
shoulder height adjuster is set to the
lowest position. Make sure the B-pillar
upper trim panel is correctly located on
the safety belt shoulder height adjuster.
6. Disconnect the side impact sensor electri- 1. To install, reverse the removal procedure.
cal connector. 2. Initialize the door window motors. For
additional information, refer to Section
501-11.

7. Remove the side impact sensor.

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501-20B-153 Supplemental Restraint System 501-20B-153

REMOVAL AND INSTALLATION

Crash Sensor

Removal 3. Disconnect the crash sensor electrical

connector.
WARNING: To avoid accidental
deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
4. Remove the crash sensor.
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.
2. Remove the radiator grille.

Installation
WARNING: Make sure the crash sensor
locating tang is correctly located in the
grill opening reinforcement panel
bracket. Failure to follow this instruction
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-20B-154 Supplemental Restraint System 501-20B-154

REMOVAL AND INSTALLATION

Air Bag Control Module (33 650 0)

Removal 4. Remove the air bag control module.

WARNING: To avoid accidental
deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to Installation
follow this instruction may result in
personal injury. WARNING: Never probe the electrical
connectors of air bag modules or any
WARNING: Never probe the electrical other supplemental restraint system
connectors of air bag modules or any component. Failure to follow this
other supplemental restraint system instruction may result in personal injury.
component. Failure to follow this 1. To install, reverse the removal procedure.
instruction may result in personal injury.
1. Disconnect the battery ground cable. For 2. WARNING: New air bag control
additional information, refer to Section modules must be configured following
414-01. installation. Failure to follow this
2. Remove the floor console. For additional instruction may result in personal
information, refer to Section 501-12. injury.
3. Disconnect the air bag control module If installing a new air bag control module,
electrical connectors. configure the air bag control module using
WDS.
3. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-20B-155 Supplemental Restraint System 501-20B-155

REMOVAL AND INSTALLATION

Driver Air Bag Module (40 700 0)

Removal
WARNING: Painting over the driver air
WARNING: To avoid accidental bag module trim cover or instrument
deployment the air bag control module panel could lead to deterioration of the
backup power supply must be depleted. trim cover and air bags. Do not for any
Wait at least one minute after reason attempt to paint discolored or
disconnecting the battery ground damaged air bag module trim covers or
cable(s) before commencing any repair instrument panel. Install a new
or adjustment to the supplemental component. Failure to follow this
restraint system (SRS), or any instruction may result in personal injury.
component(s) adjacent to the SRS 1. Disconnect the battery ground cable. For
sensors. Failure to follow these additional information, refer to Section
instructions may result in personal 414-01.
injury. 2. NOTE: Turn the steering wheel to access the
air bag module retaining screws.
WARNING: Always wear safety glasses
when working on an air bag equipped Detach the driver air bag module from the
vehicle and when handling an air bag steering wheel.
module. Failure to follow this instruction
may result in personal injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in 3. Disconnect the horn switch electrical con-
personal injury. nector.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.

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501-20B-156 Supplemental Restraint System 501-20B-156

REMOVAL AND INSTALLATION (Continued)

4. Remove the driver air bag module. 6. Disconnect the horn switch electrical con-
• Disconnect the driver air bag module elec- nectors.
trical connectors.

7. Remove the horn switch.

5. WARNING: The driver air bag module
should only be inverted long enough
for the horn switch contact plate to be
removed. Handle with extreme care
making sure that, if for any reason this
procedure is interrupted, the driver air
bag module is turned the correct way
up, with the trim cover side
uppermost. Failure to follow these
instructions may result in personal
injury.
NOTE: If a new driver air bag module is being
installed, the horn switch must be removed from
the existing driver air bag module.
Detach the horn switch wiring harness 8. Remove the horn switch contact plate from
from the horn switch. the driver air bag module.

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501-20B-157 Supplemental Restraint System 501-20B-157

REMOVAL AND INSTALLATION (Continued)

Installation
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction
may result in personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
WARNING: Painting over the driver air
bag module trim cover or instrument
panel could lead to deterioration of the
trim cover and air bags. Do not for any
reason attempt to paint discolored or
damaged air bag module trim covers or
instrument panel. Install a new
component. Failure to follow this
instruction may result in personal injury.
WARNING: The driver air bag module
should only be inverted long enough for
the horn switch contact plate to be
installed. Handle with extreme care
making sure that, if for any reason this
procedure is interrupted, the driver air
bag module is turned the correct way up,
with the trim cover side uppermost.
Failure to follow these instructions may
result in personal injury.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-20B-158 Supplemental Restraint System 501-20B-158

REMOVAL AND INSTALLATION

Passenger Air Bag Module (40 701 0)

Removal
WARNING: Painting over the driver air
WARNING: To avoid accidental bag module trim cover or instrument
deployment the air bag control module panel could lead to deterioration of the
backup power supply must be depleted. trim cover and air bags. Do not for any
Wait at least one minute after reason attempt to paint discolored or
disconnecting the battery ground damaged air bag module trim covers or
cable(s) before commencing any repair instrument panel. Install a new
or adjustment to the supplemental component. Failure to follow this
restraint system (SRS), or any instruction may result in injury.
component(s) adjacent to the SRS 1. Disconnect the battery ground cable. For
sensors. Failure to follow these additional information, refer to Section
instructions may result in personal 414-01.
injury. 2. Detach the damper from the glove
compartment.
WARNING: Always wear safety glasses
1. Open the glove compartment to access the
when working on an air bag equipped
damper.
vehicle and when handling an air bag
module. Failure to follow this instruction 2. Push the top of the damper away from the
may result in personal injury. glove compartment.

WARNING: To minimize the possibility of

premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
3. Fully open the glove compartment.
WARNING: To minimize the possibility of
• Press the sides of the glove compartment
premature deployment, live air bag
towards the center to release the glove
modules must only be placed on work
compartment stops.
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.

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501-20B-159 Supplemental Restraint System 501-20B-159

REMOVAL AND INSTALLATION (Continued)

4. Remove the glove compartment. 7. CAUTION: The passenger air bag

• Detach the hinges. module retaining bolts must only be
used three times.
NOTE: After removal, stamp the passenger air
bag module retaining bolts with a center punch to
indicate usage.
Detach the passenger air bag module from
the cross-vehicle beam.

5. Detach the glove compartment latch from

the instrument panel and position to one
side.

8. CAUTION: The passenger air bag

module retaining bolts must only be
used three times.
NOTE: After removal, stamp the passenger air
bag module retaining bolts with a center punch to
indicate usage.
Remove the passenger air bag module.

6. Disconnect the passenger air bag module

electrical connectors.

Installation
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction
may result in personal injury.

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501-20B-160 Supplemental Restraint System 501-20B-160

REMOVAL AND INSTALLATION (Continued)

WARNING: To minimize the possibility of

injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
WARNING: Painting over the driver air
bag module trim cover or instrument
panel could lead to deterioration of the
trim cover and air bags. Do not for any
reason attempt to paint discolored or
damaged air bag module trim covers or
instrument panel. Install a new
component. Failure to follow this
instruction may result in injury.
1. CAUTION: If a new passenger air bag
module is being installed, always use
the new nuts and bolts contained in
the service kit.
To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-20B-161 Supplemental Restraint System 501-20B-161

REMOVAL AND INSTALLATION

Side Air Bag Module (40 698 0)

Removal
WARNING: Always wear safety glasses 3. Detach the backrest cover tensioning
when working on an air bag equipped cords from the backrest.
vehicle and when handling an air bag
module. Failure to follow this instruction
may result in personal injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to 4. Roll the backrest cover up the backrest to
follow this instruction may result in access the side air bag module.
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
1. Remove the front seat. For additional 5. Disconnect the side air bag module elec-
information, refer to Section 501-10. trical connector.
2. Detach the backrest cover from the
underside of the seat.
• Detach the retaining strip.

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501-20B-162 Supplemental Restraint System 501-20B-162

REMOVAL AND INSTALLATION (Continued)

6. NOTE: Note the position of the ground cable Installation
attached to the side air bag module lower
retaining screw and the locating tangs on the 1. WARNING: Always wear safety glasses
rear of the side air bag module to aid when working on an air bag equipped
installation. vehicle and when handling an air bag
module. Failure to follow this
Remove the side air bag module.
instruction may result in personal
injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
WARNING: Make sure the front seat
backrest cover tensioning cords are
correctly installed and that the cover is
correctly aligned to the backrest frame.
An incorrectly installed backrest cover
may impair deployment of the side air
bag. Failure to follow this instruction
may result in personal injury.
To install, reverse the removal procedure.

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501-20B-163 Supplemental Restraint System 501-20B-163

REMOVAL AND INSTALLATION

Side Air Curtain Module — 4-Door

Removal 2. Detach the front and rear door opening

weatherstrips from around the upper part
WARNING: To avoid accidental of the door openings.
deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction 3. Remove the A-pillar trim panel. For
may result in personal injury. additional information, refer to Section
WARNING: To minimize the possibility of 501-05.
premature deployment, do not use radio 4. Detach the headliner wiring harness from
key code savers when working on the the left-hand A-pillar or the rear window
supplemental restraint system. Failure to washer tube from the right-hand A-pillar as
follow this instruction may result in necessary (left-hand A-pillar shown).
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
All vehicles
1. Disconnect the battery ground cable. For
additional information, refer to Section
414-01.

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501-20B-164 Supplemental Restraint System 501-20B-164

REMOVAL AND INSTALLATION (Continued)

5. Lever open the covers to expose the
9. Lever open the cover to expose the screw
screws and remove the passenger assist
and remove the sun visor retaining clip.
handles.

10. Detach the rear interior lamp from the

6. Move the front safety belt shoulder height
headliner (if equipped).
adjuster to its lowest position.
7. Detach the B-pillar upper trim panel from
the B-pillar and position it to one side.
1. Detach the locating tangs from the B-pillar
lower trim panel.
2. Remove the screw cover.
3. Remove the screw.

11. Disconnect the electrical connectors and

remove the rear interior lamp (if
equipped).

8. Remove the sun visor.

12. Pull down on the rear interior lamp

opening to detach the headliner spacer
adhesive fixing from the roof panel.

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501-20B-165 Supplemental Restraint System 501-20B-165

REMOVAL AND INSTALLATION (Continued)

Vehicles with roof opening panel 17. Remove the parcel shelf retaining clips
13. Remove the roof opening panel weather- and pull the parcel shelf forward.
strip.

18. Detach the C-pillar trim panel and posi-

All vehicles tion it to one side.
14. Remove the C-pillar lower trim panel
(vehicles with trim panel shown vehicles
with seat bolster similar).
• Remove the C-pillar lower trim panel re-
taining screws.

19. Remove the high mounted stoplamp

cover.

15. Fold down the rear seat backrests.

16. Remove the rear seat backrest latch cov-
ers.

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501-20B-166 Supplemental Restraint System 501-20B-166

REMOVAL AND INSTALLATION (Continued)

20. Disconnect the electrical connector and 24. NOTE: Note the routing of the retaining cord,
remove the high mounted stoplamp. to aid installation.
Remove the side air curtain module front
retaining bolts (headliner shown removed
for clarity).

21. Lower the headliner and rest it on the

front seat backrest head restraint.
22. Disconnect the side air curtain module
electrical connector. 25. NOTE: Note the position of the locating
tangs, to aid installation.
Remove the side air curtain module
(headliner shown removed for clarity).

23. NOTE: Note the routing of the retaining cord,

to aid installation.
Remove the side air curtain module rear
retaining bolts.
Installation
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction
may result in personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.

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501-20B-167 Supplemental Restraint System 501-20B-167

REMOVAL AND INSTALLATION (Continued)

WARNING: To minimize the possibility of

premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
NOTE: Make sure the front safety belt shoulder
height adjuster locking control is correctly located
on the safety belt shoulder height adjuster.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

G37889 en 08/2002 2003.0 Mondeo

501-20B-168 Supplemental Restraint System 501-20B-168

REMOVAL AND INSTALLATION

Side Air Curtain Module — 5-Door

Removal 2. Detach the front and rear door opening

weatherstrips from around the upper part
WARNING: To avoid accidental of the door openings.
deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction 3. Remove the A-pillar trim panel. For
may result in personal injury. additional information, refer to Section
WARNING: To minimize the possibility of 501-05.
premature deployment, do not use radio 4. Detach the headliner wiring harness from
key code savers when working on the the left-hand A-pillar or the rear window
supplemental restraint system. Failure to washer tube from the right-hand A-pillar as
follow this instruction may result in necessary (left-hand A-pillar shown).
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
All vehicles
1. Disconnect the battery ground cable.
For additional information, refer to Section
414-01.

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501-20B-169 Supplemental Restraint System 501-20B-169

REMOVAL AND INSTALLATION (Continued)

5. Lever open the covers to expose the

9. Lever open the cover to expose the screw
screws and remove the passenger assist
and remove the sun visor retaining clip.
handles.

10. Detach the rear interior lamp from the

6. Move the front safety belt shoulder height
headliner (if equipped).
adjuster to its lowest position.
7. Detach the B-pillar upper trim panel from
the B-pillar and position it to one side.
1. Detach the locating tangs from the B-pillar
lower trim panel.
2. Remove the screw cover.
3. Remove the screw.

11. Disconnect the electrical connectors and

remove the rear interior lamp (if
equipped).

8. Remove the sun visor.

12. Pull down on the rear interior lamp

opening to detach the headliner spacer
adhesive fixing from the roof panel.

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501-20B-170 Supplemental Restraint System 501-20B-170

REMOVAL AND INSTALLATION (Continued)

Vehicles with roof opening panel 16. Remove the C-pillar upper trim panel.
13. Remove the roof opening panel weather- • Detach the C-pillar upper trim panel retain-
strip. ing clips and disconnect the rear window
washer tube from the right-hand C-pillar
trim panel as necessary.

All vehicles
14. Detach the liftgate opening weatherstrip
from the C-pillar. 17. Remove the rear seat backrest outer
head restraint.
18. Detach the C-pillar center trim panel and
position it to one side.
1. Remove the screws.
2. Release the clip.

15. Remove the C-pillar upper trim panel

retaining screws.
• Remove the C-pillar upper trim panel
blanking plugs and retaining screws.

19. Remove the headliner retaining clips.

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501-20B-171 Supplemental Restraint System 501-20B-171

REMOVAL AND INSTALLATION (Continued)

23. NOTE: Note the routing of the retaining cord

20. Lower the headliner and rest it on the
to aid installation.
front seat backrest head restraint.
21. Disconnect the side air curtain module Remove the side air curtain module front
electrical connector. retaining bolt (headliner shown removed
for clarity).

22. NOTE: Note the routing of the retaining cord

to aid installation. 24. NOTE: Note the position of the locating tangs
to aid installation.
Remove the side air curtain module rear
retaining bolts. Remove the side air curtain module
(headliner shown removed for clarity).

Installation
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction
may result in personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.

G70856 en 08/2002 2003.0 Mondeo

501-20B-172 Supplemental Restraint System 501-20B-172

REMOVAL AND INSTALLATION (Continued)

WARNING: To minimize the possibility of

premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
NOTE: Make sure the front safety belt shoulder
height adjuster locking control is correctly located
on the safety belt shoulder height adjuster.
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-20B-173 Supplemental Restraint System 501-20B-173

REMOVAL AND INSTALLATION

Side Air Curtain Module — Wagon

Removal 2. Detach the front and rear door opening

weatherstrips from around the upper part
WARNING: To avoid accidental of the door openings.
deployment, the air bag control module
backup power supply must be depleted.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instructions may result in personal
injury.
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction 3. Remove the A-pillar trim panel. For
may result in personal injury. additional information, refer to Section
WARNING: To minimize the possibility of 501-05.
premature deployment, do not use radio 4. Detach the headliner wiring harness from
key code savers when working on the the left-hand A-pillar or the rear window
supplemental restraint system. Failure to washer tube from the right-hand A-pillar as
follow this instruction may result in necessary (left-hand A-pillar shown).
personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
All vehicles
1. Disconnect the battery ground cable.
For additional information, refer to Section
414-01.

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501-20B-174 Supplemental Restraint System 501-20B-174

REMOVAL AND INSTALLATION (Continued)

5. Lever open the covers to expose the
9. Lever open the cover to expose the screw
screws and remove the passenger assist
and remove the sun visor retaining clip.
handles.

10. Detach the rear interior lamp from the

6. Move the front safety belt shoulder height
headliner (if equipped).
adjuster to its lowest position.
7. Detach the B-pillar upper trim panel from
the B-pillar and position it to one side.
1. Detach the locating tangs from the B-pillar
lower trim panel.
2. Remove the screw cover.
3. Remove the screw.

11. Disconnect the electrical connectors and

remove the rear interior lamp (if
equipped).

8. Remove the sun visor.

12. Pull down on the rear interior lamp

opening to detach the headliner spacer
adhesive fixing from the roof panel.

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501-20B-175 Supplemental Restraint System 501-20B-175

REMOVAL AND INSTALLATION (Continued)

Vehicles with roof opening panel 16. Remove the load space upper trim panel.
13. Remove the roof opening panel weather- • Remove the load space upper trim panel
strip. retaining screws.

All vehicles
17. CAUTION: The bolt securing the
14. Detach the liftgate opening weatherstrip
safety belt anchor is held captive by a
from the D-pillar.
paper washer. The bolt, spacer and
paper washer must remain on the
safety belt anchor at all times when
the safety belt is detached or
removed.
Detach the safety belt upper anchor from
the C-pillar.
1. Detach the bolt cover.
2. Remove the bolt.

15. Remove the D-pillar trim panel retaining

screw and remove the D-pillar trim panel.
• Detach the D-pillar trim panel retaining
clips and disconnect the rear window
washer tube from the right-hand D-pillar
trim panel as necessary.

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501-20B-176 Supplemental Restraint System 501-20B-176

REMOVAL AND INSTALLATION (Continued)

18. Remove the C-pillar trim panel. 22. NOTE: Note the routing of the retaining cord
to aid installation.
Remove the side air curtain module rear
retaining bolts.

19. Remove the headliner retaining clips.

23. NOTE: Note the routing of the retaining cord

to aid installation.
Remove the side air curtain module front
retaining bolt (headliner shown removed
for clarity).

20. Lower the headliner and rest it on the

front seat backrest head restraint.
21. Disconnect the side air curtain module
electrical connector.

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501-20B-177 Supplemental Restraint System 501-20B-177

REMOVAL AND INSTALLATION (Continued)

24. NOTE: Note the position of the locating tangs

to aid installation.
Remove the side air curtain module
(headliner shown removed for clarity).

Installation
WARNING: Always wear safety glasses
when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow this instruction
may result in personal injury.
WARNING: To minimize the possibility of
injury in the event of premature
deployment, always carry a live air bag
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in
personal injury.
WARNING: To minimize the possibility of
premature deployment, live air bag
modules must only be placed on work
benches which have been ground
bonded and with the trim cover facing
up. Failure to follow these instructions
may result in personal injury.
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this
instruction may result in personal injury.
NOTE: Make sure the front safety belt shoulder
height adjuster locking control is correctly located
on the safety belt shoulder height adjuster
1. To install, reverse the removal procedure.
2. Initialize the door window motors. For
additional information, refer to Section
501-11.

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501-20B-178 Supplemental Restraint System 501-20B-178

REMOVAL AND INSTALLATION

Clockspring

Removal 3. Detach the audio control switch from the

steering column lower shroud (if
WARNING: To avoid accidental equipped).
deployment, the air bag control module
• Using a thin bladed screwdriver, release
backup power supply must be depleted.
the locking tang.
Wait at least one minute after
disconnecting the battery ground
cable(s) before commencing any repair
or adjustment to the supplemental
restraint system (SRS), or any
component(s) adjacent to the SRS
sensors. Failure to follow these
instruction may result in personal injury.
WARNING: To minimize the possibility of
premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure to
follow this instruction may result in
personal injury.
WARNING: Never probe the electrical 4. Remove the audio control switch (if
connectors of air bag modules or any equipped).
other supplemental restraint system • Disconnect the electrical connector.
component. Failure to follow this
instruction may result in personal injury.
1. Remove the instrument panel lower panel.
1. Remove the screws.
2. Release the clips.

2. Remove the steering wheel. For additional

information, refer to Section 211-04.

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501-20B-179 Supplemental Restraint System 501-20B-179

REMOVAL AND INSTALLATION (Continued)

5. Detach the steering column upper shroud 8. NOTE: Note the routing of the clockspring
from the lower shroud. wiring harness to aid installation.
1. Using a thin bladed screwdriver, release Detach the spreader plate from the steer-
the two clips (one each side). ing column and position it to one side.
2. Detach the shroud.

9. Disconnect the clockspring electrical con-

6. Remove the steering column lower shroud. nector.

7. Detach the multifunction switches from the 10. Remove the clockspring.
clockspring and position them to one side. • Release the locking tangs from the steering
column.

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501-20B-180 Supplemental Restraint System 501-20B-180

REMOVAL AND INSTALLATION (Continued)

3. CAUTION: Make sure that the

Installation clockspring wiring harness is routed
down the spreader plate depression
WARNING: Never probe the electrical and, following the installation of the
connectors of air bag modules or any spreader plate, that the clockspring
other supplemental restraint system electrical connector is fully
component. Failure to follow this connected.
instruction may result in personal injury. Attach the spreader plate to the steering
1. Install the clockspring. column.
• Make sure the retaining tangs lock into po-
sition on the steering column.

4. Attach the multifunction switches to the

clockspring.
2. Connect the clockspring electrical connec-
tor.

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501-20B-181 Supplemental Restraint System 501-20B-181

REMOVAL AND INSTALLATION (Continued)

5. Install the steering column lower shroud. 7. WARNING: Incorrect centralization

may result in premature component
failure. If in doubt when centralizing
the clockspring, repeat the
centralizing procedure. Failure to
follow this instruction may result in
personal injury.
Centralize the clockspring.
1. Turn the clockspring in a counterclockwise
direction until resistance is felt
(approximately two and one half turns from
the central position).
2. Turn the clockspring in a clockwise direc-
tion, until the arrow marked on the rotor of
the clockspring aligns with the raised 'V'
6. Install the audio control switch (if section at the 12 o'clock position on the
equipped). outer cover of the clockspring (approxi-
• Connect the electrical connector. mately two and one half turns).

8. Attach the steering column upper shroud

to the lower shroud.

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501-20B-182 Supplemental Restraint System 501-20B-182

REMOVAL AND INSTALLATION (Continued)

9. CAUTION: If there is any break

between centralizing the clockspring
and installing the steering wheel, or
the vehicle is left unattended by the
technician, the centralizing procedure
MUST be repeated.
Install the steering wheel. For additional
information, refer to Section 211-04.
10. Install the instrument panel lower panel.
1. Install the clips.
2. Install the screws.

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501-20B-183 Supplemental Restraint System 501-20B-183

REMOVAL AND INSTALLATION

Occupant Classification Sensor

Removal
1. NOTE: The occupant classification sensor is
an integral part of the passenger seat cushion
and cannot be serviced separately. If the
occupant classification sensor is found to be
unserviceable, following the correct diagnosis
and testing, a new passenger seat cushion
must be installed.
Remove the passenger seat cushion. For
additional information, refer to Section
501-10.

Installation
1. To install, reverse the removal procedure.

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502-00-1 Uni-Body, Subframe and Mounting System 502-00-1

SECTION 502-00 Uni-Body, Subframe and Mounting

System
VEHICLE APPLICATION: 2003.0 Mondeo

CONTENTS PAGE
SPECIFICATIONS

Specifications .................................................................................................................... 502-00-2

REMOVAL AND INSTALLATION

Subframe........................................................................................................................... 502-00-3

08/2002 2003.0 Mondeo

502-00-2 Uni-Body, Subframe and Mounting System 502-00-2

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Lower arm front retaining bolts
1. Stage 80 59 -
2. Stage 60 Degrees 60 Degrees 60 Degrees
Lower arm rear retaining bolts
1. Stage 90 66 -
2. Stage 60 Degrees 60 Degree 60 Degree
Stabilizer bar to the subframe 48 35 -
Steering gear to the subframe 130 96 -
Rear subframe retaining bolts 142 105 -
Subframe bracket to the body 10 - 89
Front subframe retaining bolts 142 105 -
Lower arm ball joint pinch bolt to the wheel 83 61 -
knuckle
Engine support insulator to the subframe 80 59 -
Engine support insulator to the engine 80 59 -
Stabilizer connecting link to the suspension strut 48 35 -
Radiator support bracket retaining bolts to the sub- 25 18 -
frame
Engine undershield retaining bolts 10 - 89
Hose bracket to the subframe 10 - 89

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502-00-3 Uni-Body, Subframe and Mounting System 502-00-3

REMOVAL AND INSTALLATION

Subframe
REMOVAL AND INSTALLATION

Removal
Special Tool(s)
All vehicles
Remover/Installer, Rear
1. NOTE: Make sure the road wheels are in the
Suspension Bushing
straight ahead position.
205-050 (15-014)
Centralize the steering.

Alignment Pins, Subframe

205-316 (15-097A)

Wrench, Steering Gear

211-270 (13-028)

Angle Gauge, Bolt Tightening

2. Using cable ties, support the radiator on
303-174 (21-540) both sides.

General Equipment
Transmission jack
Wooden blocks

Name Specification
Washer E830 819 571

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502-00-4 Uni-Body, Subframe and Mounting System 502-00-4

REMOVAL AND INSTALLATION (Continued)

3. Raise and support the vehicle. For 7. Remove the radiator support bracket on
additional information, refer to Section both sides.
100-02. 1. Remove the hose bracket (if equipped).
4. Remove the front wheels and tires. For 2. Remove the radiator support bracket.
additional information, refer to Section
204-04.
5. Remove the engine undershield (if
equipped).

Vehicles with diesel engine

8. Remove the air intake hose.

6. Remove the splash shield.

9. Remove the turbocharger outlet hose.

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502-00-5 Uni-Body, Subframe and Mounting System 502-00-5

REMOVAL AND INSTALLATION (Continued)

All vehicles 13. Detach the catalyst monitor sensor wiring

10. Detach the stabilizer bar connecting link harness from the subframe.
from the suspension strut on both sides.

Vehicles with 1.8L, 2.0L or diesel engine

11. Detach the radiator cooling fan wiring 14. Remove the exhaust flexible pipe. For
harness from the subframe. additional information, refer to Section
309-00.
Vehicles with 2.5L engine
15. Remove the dual converter Y-pipe. For
additional information, refer to Section
309-00.
Vehicles with 3.0L engine
16. Remove the catalytic converters. For
additional information, refer to Section
309-00.
Vehicles with xenon headlamps
17. Disconnect the headlamp leveling sensor
electrical connector.

All except vehicles with diesel engine

12. Disconnect the catalyst monitor sensor
electrical connector.

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502-00-6 Uni-Body, Subframe and Mounting System 502-00-6

REMOVAL AND INSTALLATION (Continued)

18. Detach the headlamp leveling sensor wir- 21. CAUTION: Do not pull down the lower
ing harness from the subframe. arm, to prevent the lower arm hydro-
bushing from damage.
Remove the lower arm ball joint retaining
nut and bolt.

All Vehicles
19. Remove the engine rear support insula-
tor.
22. Remove the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

20. Using two suitable wooden blocks and

suitable transmission jack, support the
subframe.
23. Remove the subframe front retaining
bolts on both sides.

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502-00-7 Uni-Body, Subframe and Mounting System 502-00-7

REMOVAL AND INSTALLATION (Continued)

24. CAUTION: Lower the subframe 27. CAUTION: Protect the ball joint seal
uniformly, to prevent the lower arm using a soft cloth to prevent damage.
hydro-bushing from damage.
Detach the lower arm ball joint from the
Using the transmission jack, lower the wheel knuckle.
subframe approximately 150 mm. • Remove the heat shield.

25. Remove the splash shield on both sides. 28. Using the transmission jack, lower the
subframe uniformly.

26. Using the special tool, detach the

steering gear from the subframe. 29. Remove the stabilizer bar (two bolts each
• Support the steering gear, using cable ties. side).

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502-00-8 Uni-Body, Subframe and Mounting System 502-00-8

REMOVAL AND INSTALLATION (Continued)

30. Remove the lower arms (two bolts each Installation
side).
All vehicles
1. NOTE: Use new bushings.
NOTE: Make sure correct orientation of
bushings. Slot on inner core of bushing has to
point to vehicle longitudinal axis.
Using the special tool, install the subframe
bushings.

31. Using the special tool, remove the sub-

frame bushings.

2. NOTE: Use new bolts and nuts.

Install the lower arms.
1. Install the lower arm front retaining bolt in
two stages.
• Stage 1: 80 Nm.
• Stage 2: 60 degrees.
2. Install the lower arm rear retaining bolt in
two stages.
• Stage 1: 90 Nm.
• Stage 2: 60 degrees.

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502-00-9 Uni-Body, Subframe and Mounting System 502-00-9

REMOVAL AND INSTALLATION (Continued)

3. Install the stabilizer bar (two bolts each

6. Using the special tool, attach the steering
side).
gear to the subframe.
• Remove the cable ties.

4. Using the transmission jack, position the

subframe and lift it towards the body until
the distance of the subframe to body is 7. Install the splash shield on both sides.
approximately 150 mm.

8. Using the transmission jack, position the

subframe.
5. CAUTION: Make sure the heat shield is
installed to prevent damage to the ball
joint.
Attach the lower arm to the wheel knuckle
on both sides.
• Install the heat shield.

9. Using the special tools and a suitable

washer, align the subframe.
1. Insert the washer, with inside diameter 22
mm, outside diameter 44 mm and height 5

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502-00-10 Uni-Body, Subframe and Mounting System 502-00-10

REMOVAL AND INSTALLATION (Continued)

mm, into the subframe above the lower
alignment hole.
11. CAUTION: While tightening the
2. Insert the alignment pin through the
subframe retaining bolts, make sure
subframe alignment holes and the washer.
the subframe does not move.
3. Slide the locking plates on top of the
washer and into the groove of the tool and Install the subframe front retaining bolts.
tighten the alignment pin sleeve. • Lower and remove the transmission jack.

10. CAUTION: While tightening the 12. Remove the special tools.
subframe retaining bolts, make sure
the subframe does not move.
Install the subframe rear retaining bolts
and the subframe bracket retaining bolts
on both sides.

13. NOTE: The lower arm pinch bolt must be

installed from the rear.
Install the lower arm ball joint pinch bolt
on both sides.

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502-00-11 Uni-Body, Subframe and Mounting System 502-00-11

REMOVAL AND INSTALLATION (Continued)

Vehicles with 2.5L engine

14. Install the engine rear support insulator.
18. Install the dual converter Y-pipe. For
additional information, refer to Section
309-00.
Vehicles with 3.0L engine
19. Install the catalytic converters. For
additional information, refer to Section
309-00.
All Vehicles
20. Install the stabilizer bar connecting link
to the suspension strut on both sides.

Vehicles with xenon headlamps

15. Attach the headlamp leveling sensor wir-
ing harness to the subframe.

21. Attach the radiator cooling fan wiring

harness to the subframe.

16. Connect the headlamp leveling sensor

electrical connector.

Vehicles with 1.8L, 2.0L or diesel engine

17. Install the exhaust flexible pipe. For
additional information, refer to Section
309-00.

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502-00-12 Uni-Body, Subframe and Mounting System 502-00-12

REMOVAL AND INSTALLATION (Continued)

All except vehicles with diesel engine 25. Install the air intake hose.
22. Attach the catalyst monitor sensor wiring
harness to the subframe.

All vehicles
26. Install the radiator support brackets on
23. Connect the catalyst monitor sensor elec- both sides.
trical connector. 1. Install the radiator support brackets.
2. Install the hose bracket (if equipped).

Vehicles with diesel engine

24. Install the turbocharger outlet hose.
27. Install the splash shield.

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502-00-13 Uni-Body, Subframe and Mounting System 502-00-13

REMOVAL AND INSTALLATION (Continued)

28. Install the engine undershield (if

equipped).

29. Install the wheels and tires. For additional

information, refer to Section 414-01.
30. Lower the vehicle.
31. Remove the cable ties.

32. Check the toe setting and adjust as

necessary. For additional information,
refer to Section 204-00.

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