Ford - Escape 2wd - Workshop Manual - 2003 - 2003

Factory Workshop Manual Make Ford Model Escape 2wd Engine and year L4-122 2.0L DOHC VIN B Zetec SFI (2003) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 P0010 - P0014: Testing and Inspection P0010 For diagnosis of code P0010 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 9 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 10 P0010 - P0014: Testing and Inspection P0011 For diagnosis of code P0011 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 11 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 12 P0010 - P0014: Testing and Inspection P0012 For diagnosis of code P0012 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 13 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 P0020 - P0024: Testing and Inspection P0020 For diagnosis of code P0020 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 18 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 19 P0020 - P0024: Testing and Inspection P0021 For diagnosis of code P0021 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 20 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 21 P0020 - P0024: Testing and Inspection P0022 For diagnosis of code P0022 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 22 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044, ( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 P0040 - P0044: Testing and Inspection P0040 For diagnosis of code P0040 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044, ( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > Page 27 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044, ( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > Page 28 P0040 - P0044: Testing and Inspection P0041 For diagnosis of code P0041 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044, ( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > Page 29 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054, ( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 P0050 - P0054: Testing and Inspection P0053 For diagnosis of code P0053 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054, ( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > Page 34 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054, ( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > Page 35 P0050 - P0054: Testing and Inspection P0054 For diagnosis of code P0054 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054, ( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > Page 36 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0055 - P0059, ( P0056 P0057 P0058 0055 0056 0057 0058 0059 ) > System Information > System Diagnosis P0055 - P0059: Testing and Inspection For diagnosis of code P0059 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0060 - P0064, ( P0061 P0062 P0063 0060 0061 0062 0063 0064 ) > System Information > System Diagnosis P0060 - P0064: Testing and Inspection For diagnosis of code P0060 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0065 - P0069, ( P0066 P0067 P0068 0065 0066 0067 0068 0069 ) > System Information > System Diagnosis P0065 - P0069: Testing and Inspection For diagnosis of code P0068 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 51 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 52 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 53 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 58 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 59 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 60 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 61 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 62 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 63 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 64 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 69 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 70 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart Bxxx - P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 71 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 P0115 - P0119: Testing and Inspection P0116 For diagnosis of code P0116 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 76 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 77 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 78 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 79 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 80 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 85 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 86 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 87 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 88 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 89 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 94 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 95 P0125 - P0129: Testing and Inspection P0128 For diagnosis of code P0128 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 96 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 101 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 102 P0130 - P0134: Testing and Inspection P0132 For diagnosis of code P0132 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 103 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 104 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 105 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 110 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 111 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 112 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 113 P0135 - P0139: Testing and Inspection P0138 For diagnosis of code P0138 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 114 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > Page 118 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis P0145 - P0149: Testing and Inspection For diagnosis of code P0148 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > Page 122 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 127 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 128 P0150 - P0154: Testing and Inspection P0152 For diagnosis of code P0152 refer to chart P0116 - P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 129 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 130 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 131 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 136 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 137 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 138 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 139 P0155 - P0159: Testing and Inspection P0158 For diagnosis of code P0158 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 140 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis > Page 144 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 149 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 150 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 151 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 152 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 153 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis P0175 - P0179: Testing and Inspection For diagnosis of code P0175 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > Page 157 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 162 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 163 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 164 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 165 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 166 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 167 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 168 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 173 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 174 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 175 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 176 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 177 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 178 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 179 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 P0195 - P0199: Testing and Inspection P0196 For diagnosis of code P0196 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 184 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 185 P0195 - P0199: Testing and Inspection P0197 For diagnosis of code P0197 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 186 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 187 P0195 - P0199: Testing and Inspection P0198 For diagnosis of code P0198 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 188 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 194 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 195 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 196 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 197 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 198 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 199 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 200 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 205 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 206 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 207 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 208 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 209 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 210 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 211 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 212 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 213 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 218 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 219 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 220 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 221 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 222 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis P0215 - P0219: Testing and Inspection For diagnosis of code P0219 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > Page 226 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 P0220 - P0224: Testing and Inspection P0221 For diagnosis of code P0221 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 231 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 232 P0220 - P0224: Testing and Inspection P0222 For diagnosis of code P0222 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 233 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 234 P0220 - P0224: Testing and Inspection P0223 For diagnosis of code P0223 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 235 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0153 - P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 240 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 241 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 242 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 243 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 244 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 P0295 - P0299: Testing and Inspection P0297 For diagnosis of code P0297 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 > Page 249 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 > Page 250 P0295 - P0299: Testing and Inspection P0298 For diagnosis of code P0298 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 > Page 251 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 257 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 258 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 259 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 260 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 261 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 262 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 263 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 264 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 265 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 270 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 271 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 272 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 273 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 274 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 275 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 276 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 277 P0305 - P0309: Testing and Inspection P0309 For diagnosis of code P0309 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 278 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis > Page 282 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 P0315 - P0319: Testing and Inspection P0315 For diagnosis of code P0315 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 287 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 288 P0315 - P0319: Testing and Inspection P0316 For diagnosis of code P0316 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 289 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis > Page 293 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 298 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 299 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 300 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 305 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 306 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 307 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > Page 311 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349, ( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis P0345 - P0349: Testing and Inspection For diagnosis of code P0345 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349, ( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis > Page 315 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 320 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 321 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 322 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 323 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 324 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 325 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 326 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 327 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 328 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 333 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 334 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 335 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 336 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 337 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 338 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 339 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 340 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 341 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis > Page 345 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 P0400 - P0404: Testing and Inspection P0400 For diagnosis of code P0400 refer to chart P0231 - P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 351 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 352 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 353 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 354 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 355 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 356 P0400 - P0404: Testing and Inspection P0403 For diagnosis of code P0403 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 357 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 P0405 - P0409: Testing and Inspection P0405 For diagnosis of code P0405 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 362 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 363 P0405 - P0409: Testing and Inspection P0406 For diagnosis of code P0406 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 364 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 369 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 370 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 371 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 382 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 383 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0445 - P0449, ( P0446 P0447 P0448 0445 0446 0447 0448 0449 ) > System Information > System Diagnosis P0445 - P0449: Testing and Inspection For diagnosis of code P0446 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 391 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 392 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 393 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 394 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 395 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 400 P0455 - P0459: Testing and Inspection P0456 For diagnosis of code P0456 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 401 P0455 - P0459: Testing and Inspection P0457 For diagnosis of P0457 refer to the system experiencing the problem. Computers and Control Systems P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 402 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 407 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 408 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 409 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 410 P0460 - P0464: Testing and Inspection P0462 For diagnosis of code P0462 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 411 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 412 P0460 - P0464: Testing and Inspection P0463 For diagnosis of code P0463 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 413 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 P0480 - P0484: Testing and Inspection P0480 For diagnosis of code P0480 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 418 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 419 P0480 - P0484: Testing and Inspection P0481 For diagnosis of code P0481 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 420 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 421 P0480 - P0484: Testing and Inspection P0482 For diagnosis of code P0482 refer to chart P0401 - P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 422 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of code P0500 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 428 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 429 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 430 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 431 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 432 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 P0505 - P0509: Testing and Inspection P0505 For diagnosis of code P0505 refer to chart P0500 - P071x NOTE 16: Refer to the Diagnostic Trouble Code (DTC) Descriptions Chart for Descriptions, Possible Causes and Diagnostic Aids for the DTC in question. If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 437 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 438 P0505 - P0509: Testing and Inspection P0506 For diagnosis of code P0506 refer to chart P0500 - P071x NOTE 16: Refer to the Diagnostic Trouble Code (DTC) Descriptions Chart for Descriptions, Possible Causes and Diagnostic Aids for the DTC in question. If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 439 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 440 P0505 - P0509: Testing and Inspection P0507 For diagnosis of code P0507 refer to chart P0500 - P071x NOTE 16: Refer to the Diagnostic Trouble Code (DTC) Descriptions Chart for Descriptions, Possible Causes and Diagnostic Aids for the DTC in question. If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 441 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514, ( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis P0510 - P0514: Testing and Inspection For diagnosis of code P0511 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514, ( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis > Page 445 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0525 - P0529, ( P0526 P0527 P0528 0525 0526 0527 0528 0529 ) > System Information > System Diagnosis P0525 - P0529: Testing and Inspection For diagnosis of code P0528 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0525 - P0529, ( P0526 P0527 P0528 0525 0526 0527 0528 0529 ) > System Information > System Diagnosis > Page 449 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534, ( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis P0530 - P0534: Testing and Inspection For diagnosis of code P0534 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534, ( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > Page 453 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539, ( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 P0535 - P0539: Testing and Inspection P0537 For diagnosis of code P0537 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539, ( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 458 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539, ( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 459 P0535 - P0539: Testing and Inspection P0538 For diagnosis of code P0538 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539, ( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 460 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 465 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 466 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 467 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to NOTE 7: NOTE 7: The Vehicle ID (VID) Block must be reprogrammed. For instruction refer to the Flash VID Block Procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 473 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 474 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 P0605 - P0609: Testing and Inspection P0605 For diagnosis of code P0605 refer to NOTE 10: NOTE 10: Be sure to check for aftermarket performance products before replacing PCM. For Electronic Throttle Control vehicles, P0606 may be set with other DTC's indicating a specific failure in that system, and repairing those DTC's will fix the P0606. (Follow DTC chart for DTC's) For diagnosing P0606 alone, an internal fault in the PCM is indicated, and the PCM should be replaced. For replacement, refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 > Page 479 P0605 - P0609: Testing and Inspection P0606 For diagnosis of code P0606 refer to NOTE 10: NOTE 10: Be sure to check for aftermarket performance products before replacing PCM. For Electronic Throttle Control vehicles, P0606 may be set with other DTC's indicating a specific failure in that system, and repairing those DTC's will fix the P0606. (Follow DTC chart for DTC's) For diagnosing P0606 alone, an internal fault in the PCM is indicated, and the PCM should be replaced. For replacement, refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624, ( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 P0620 - P0624: Testing and Inspection P0620 For diagnosis of code P0620 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624, ( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 484 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624, ( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 485 P0620 - P0624: Testing and Inspection P0622 For diagnosis of code P0622 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624, ( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 486 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649, ( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis P0645 - P0649: Testing and Inspection For diagnosis of code P0645 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649, ( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis > Page 490 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664, ( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis P0660 - P0664: Testing and Inspection For diagnosis of code P0660 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664, ( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis > Page 494 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 500 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 501 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0574 refer to chart P0500 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 502 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart DTC Index B2472 - U1262 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Instrument Cluster, follow this link: See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 507 P0705 - P0709: Testing and Inspection P0707 For diagnosis of code P0707 refer to chart Part 3 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 508 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 509 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart Part 3 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 510 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart Part 6 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 515 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 516 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart Part 6 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 517 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 P0715 - P0719: Testing and Inspection P0715 For diagnosis of code P0715 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 522 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 523 P0715 - P0719: Testing and Inspection P0717 For diagnosis of code P0717 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 524 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 525 P0715 - P0719: Testing and Inspection P0718 For diagnosis of code P0718 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 526 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 531 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 532 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 533 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 534 Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0722 ( P 0722 ) For diagnosis of code P0722 refer to chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 535 Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 536 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 P0730 - P0734: Testing and Inspection P0731 For diagnosis of code P0731 refer to chart Part 2 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 541 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 542 P0730 - P0734: Testing and Inspection P0732 For diagnosis of code P0732 refer to chart Part 3 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 543 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 544 P0730 - P0734: Testing and Inspection P0733 For diagnosis of code P0733 refer to chart Part 3 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 545 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 546 P0730 - P0734: Testing and Inspection P0734 For diagnosis of code P0734 refer to chart Part 3 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 547 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0740 P0740 - P0744: Testing and Inspection P0740 For diagnosis of code P0740 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0740 > Page 552 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0740 > Page 553 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0740 > Page 554 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0740 > Page 555 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0740 > Page 556 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 P0750 - P0754: Testing and Inspection P0750 For diagnosis of code P0750 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 561 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 562 P0750 - P0754: Testing and Inspection P0751 For diagnosis of code P0751 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 563 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 564 P0750 - P0754: Testing and Inspection P0753 For diagnosis of code P0753 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 565 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 P0755 - P0759: Testing and Inspection P0755 For diagnosis of code P0755 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 570 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 571 P0755 - P0759: Testing and Inspection P0756 For diagnosis of code P0756 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 572 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 573 P0755 - P0759: Testing and Inspection P0758 For diagnosis of code P0758 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 574 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis > Page 579 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P072x - P1132 NOTE 1: DTC P1000 is ignored in KOEO an KOER Self-Test. Disregard DTC P1000 and continue as directed. If there is no link in the chart then: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 585 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 586 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 587 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 593 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 594 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 595 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis P1110 - P1114: Testing and Inspection For diagnosis of code P1112 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > Page 599 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 > Page 604 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 > Page 605 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 > Page 606 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 611 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 612 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 613 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 614 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 615 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 620 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 621 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 622 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 623 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 624 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 625 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 626 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 631 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 632 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 633 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 634 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P072x - P1132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 635 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 640 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 641 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 642 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 647 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 648 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 649 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 650 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 651 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 656 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 657 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 658 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 P1165 - P1169: Testing and Inspection P1168 For diagnosis of code P1168 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 663 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 664 P1165 - P1169: Testing and Inspection P1169 For diagnosis of code P1169 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 665 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 P1180 - P1184: Testing and Inspection P1180 For diagnosis of code P1180 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 670 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 671 P1180 - P1184: Testing and Inspection P1181 For diagnosis of code P1181 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 672 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 673 P1180 - P1184: Testing and Inspection P1184 For diagnosis of code P1184 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 674 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1195 - P1199, ( P1196 P1197 P1198 1195 1196 1197 1198 1199 ) > System Information > System Diagnosis P1195 - P1199: Testing and Inspection For diagnosis of code P1197 refer to chart DTC Index B2472 - U1262 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Instrument Cluster, follow this link: See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 683 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 684 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1137 - P1400 NOTE 6: Got to Information Bus for REM (Rear Electronics Module ) Self-test diagnostics. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 685 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 686 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1137 - P1400 NOTE 6: Got to Information Bus for REM (Rear Electronics Module ) Self-test diagnostics. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 687 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 692 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 693 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 694 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 695 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 696 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 697 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 698 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 706 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 707 P1245 - P1249: Testing and Inspection P1246 For diagnosis of P1246 refer to the system experiencing the problem. Computers and Control Systems P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 708 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Charging System DTC Index P1246 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Charging System diagnostic information, See: Starting and Charging/Charging System/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 719 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 720 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 721 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 722 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 723 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1335 - P1339, ( P1336 P1337 P1338 1335 1336 1337 1338 1339 ) > System Information > System Diagnosis P1335 - P1339: Testing and Inspection For diagnosis of code P1336 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 741 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 742 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 743 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 744 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 745 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389, ( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 P1385 - P1389: Testing and Inspection P1386 For diagnosis of code P1386 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389, ( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 > Page 750 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389, ( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 > Page 751 P1385 - P1389: Testing and Inspection P1388 For diagnosis of code P1388 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389, ( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 > Page 752 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1395 - P1399, ( P1396 P1397 P1398 1395 1396 1397 1398 1399 ) > System Information > System Diagnosis P1395 - P1399: Testing and Inspection For diagnosis of code P1397 refer to NOTE 17: NOTE 17: Refer to Charging System and diagnose the charging system concern. See: Starting and Charging/Charging System/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1137 - P1400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 761 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 762 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 763 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 768 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 769 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 770 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 771 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 772 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 773 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 774 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 P1435 - P1439: Testing and Inspection P1436 For diagnosis of code P1436 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 779 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 780 P1435 - P1439: Testing and Inspection P1437 For diagnosis of code P1437 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 781 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to chart DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 789 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 790 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 791 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 796 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 797 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 798 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 799 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 800 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 801 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 802 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 803 P1460 - P1464: Testing and Inspection P1464 For diagnosis of P1464 refer to the system experiencing the problem. Computers and Control Systems P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 804 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Heating and Air Conditioning DTC Index P1460 - P1479 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Heating and Air Conditioning diagnostic information, See: Heating and Air Conditioning/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 P1475 - P1479: Testing and Inspection P1477 For diagnosis of code P1477 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 815 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 816 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 817 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 823 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 824 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1401 - P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 825 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 826 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 827 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 828 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 829 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 834 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 835 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 836 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 841 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 842 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 843 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 844 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 845 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 846 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 847 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis > Page 851 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 856 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 857 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 858 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis > Page 862 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis > Page 866 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 P1565 - P1569: Testing and Inspection P1565 For diagnosis of code P1565 refer to Cruise Control. See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 871 P1565 - P1569: Testing and Inspection P1566 For diagnosis of code P1566 refer to Cruise Control. See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 872 P1565 - P1569: Testing and Inspection P1567 For diagnosis of code P1567 refer to Cruise Control. See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 873 P1565 - P1569: Testing and Inspection P1568 For diagnosis of code P1568 refer to Cruise Control. See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis P1570 - P1574: Testing and Inspection For diagnosis of code P1572 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Page 877 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis > Page 882 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to Emission Control Systems, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 887 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to Note 14: NOTE 14: DTC P1636 indicates the PCM has lost communication with the Inductive Signature Chip. Replace PCM. If replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 888 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to Note 7: NOTE 7: The Vehicle ID (VID) Block must be reprogrammed. For instruction refer to the Flash VID Block Procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > Page 892 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 897 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 898 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 899 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 905 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 906 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 907 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 For diagnosis of code P1705 refer to chart Part 1 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 912 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 913 P1705 - P1709: Testing and Inspection P1706 For diagnosis of code P1706 refer to chart DTC Index B2472 - U1262 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Instrument Cluster, follow this link: See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 914 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1502 - P176x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 915 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 P1710 - P1714: Testing and Inspection P1711 For diagnosis of code P1711 refer to chart Part 6 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 920 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 921 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart Part 6 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 922 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 923 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 924 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 929 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 930 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart Part 6 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 931 Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1742 P1740 - P1744: Testing and Inspection P1742 For diagnosis of code P1742 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1742 > Page 936 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1742 > Page 937 P1740 - P1744: Testing and Inspection P1743 For diagnosis of code P1743 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1742 > Page 938 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1742 > Page 939 P1740 - P1744: Testing and Inspection P1744 For diagnosis of code P1744 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1742 > Page 940 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart Part 2 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 945 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 946 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart Part 2 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 947 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis P1750 - P1754: Testing and Inspection For diagnosis of code P1751 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis > Page 951 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1755 - P1759, ( P1756 P1757 P1758 1755 1756 1757 1758 1759 ) > System Information > System Diagnosis P1755 - P1759: Testing and Inspection For diagnosis of code P1756 refer to chart Part 5 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1755 - P1759, ( P1756 P1757 P1758 1755 1756 1757 1758 1759 ) > System Information > System Diagnosis > Page 955 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis P1760 - P1764: Testing and Inspection For diagnosis of code P1760 refer to chart Part 2 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > Page 959 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 964 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 965 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P177x - P2196 NOTE 13: Go to Transfer Case. If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 966 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1785 - P1789, ( P1786 P1787 P1788 1785 1786 1787 1788 1789 ) > System Information > System Diagnosis > P1788 P1785 - P1789: Testing and Inspection P1788 For diagnosis of code P1788 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1785 - P1789, ( P1786 P1787 P1788 1785 1786 1787 1788 1789 ) > System Information > System Diagnosis > P1788 > Page 971 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1785 - P1789, ( P1786 P1787 P1788 1785 1786 1787 1788 1789 ) > System Information > System Diagnosis > P1788 > Page 972 P1785 - P1789: Testing and Inspection P1789 For diagnosis of code P1789 refer to chart Part 4 Of 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1785 - P1789, ( P1786 P1787 P1788 1785 1786 1787 1788 1789 ) > System Information > System Diagnosis > P1788 > Page 973 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis P1900 - P1904: Testing and Inspection For diagnosis of code P1900 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Page 978 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2000 - P2004, ( P2001 P2002 P2003 2000 2001 2002 2003 2004 ) > System Information > System Diagnosis P2000 - P2004: Testing and Inspection For diagnosis of code P2004 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2000 - P2004, ( P2001 P2002 P2003 2000 2001 2002 2003 2004 ) > System Information > System Diagnosis > Page 983 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 P2005 - P2009: Testing and Inspection P2005 For diagnosis of code P2005 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 988 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 989 P2005 - P2009: Testing and Inspection P2006 For diagnosis of code P2006 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 990 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 991 P2005 - P2009: Testing and Inspection P2008 For diagnosis of code P2008 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 992 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2010 - P2014, ( P2011 P2012 P2013 2010 2011 2012 2013 2014 ) > System Information > System Diagnosis P2010 - P2014: Testing and Inspection For diagnosis of code P2014 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2010 - P2014, ( P2011 P2012 P2013 2010 2011 2012 2013 2014 ) > System Information > System Diagnosis > Page 996 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019, ( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis P2015 - P2019: Testing and Inspection For diagnosis of code P2019 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019, ( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis > Page 1000 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 P2070 - P2074: Testing and Inspection P2070 For diagnosis of code P2070 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 1005 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 1006 P2070 - P2074: Testing and Inspection P2071 For diagnosis of code P2071 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 1007 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2075 - P2079, ( P2076 P2077 P2078 2075 2076 2077 2078 2079 ) > System Information > System Diagnosis P2075 - P2079: Testing and Inspection For diagnosis of code P2075 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2075 - P2079, ( P2076 P2077 P2078 2075 2076 2077 2078 2079 ) > System Information > System Diagnosis > Page 1011 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 P2195 - P2199: Testing and Inspection P2195 For diagnosis of code P2195 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1017 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1018 P2195 - P2199: Testing and Inspection P2196 For diagnosis of code P2196 refer to chart P177x - P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1019 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1020 P2195 - P2199: Testing and Inspection P2197 For diagnosis of code P2197 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1021 P2195 - P2199: Testing and Inspection P2198 For diagnosis of code P2198 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259, ( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257 P2255 - P2259: Testing and Inspection P2257 For diagnosis of code P2257 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259, ( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257 > Page 1027 P2255 - P2259: Testing and Inspection P2258 For diagnosis of code P2258 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 P2270 - P2274: Testing and Inspection P2270 For diagnosis of code P2270 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 1032 P2270 - P2274: Testing and Inspection P2271 For diagnosis of code P2271 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 1033 P2270 - P2274: Testing and Inspection P2272 For diagnosis of code P2272 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 1034 P2270 - P2274: Testing and Inspection P2273 For diagnosis of code P2273 refer to chart P2197 - Uxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 1041 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 1042 Accessory Delay Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 1043 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Application and ID Alarm Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Testing and Inspection Audio Control Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Testing and Inspection > Page 1050 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Description and Operation > Module Controlled Functions General Module: Description and Operation Module Controlled Functions MODULE CONTROLLED FUNCTIONS The multifunction module consists of the generic electronic module (GEM). The GEM controls the following features: - interval rear window wiper - battery saver - illuminated entry - headlamp control - interior lamp control - power door locks - remote keyless entry (RKE) - accessory delay - perimeter anti-theft system - door ajar output control Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Description and Operation > Module Controlled Functions > Page 1056 General Module: Description and Operation Principles of Operation (How Does It Work?) PRINCIPLES OF OPERATION The generic electronic module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a diagnostic trouble code (DTC). The ignition switch position is very important to the GEM function. Erratic or unexpected GEM function can often be traced to problems with these GEM inputs. The GEM controls a variety of systems: - interval rear window wiper - battery saver - illuminated entry - headlamp control - interior lamp control - power door locks - remote keyless entry (RKE) - accessory delay - perimeter anti-theft system - door ajar output control Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview General Module: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical Fuse - Wiring harness - Connector(s) - Circuitry - Generic electronic module (GEM) 3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: - CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). - NO RESP/NOT EQUIP for generic electronic module (GEM), go to Pinpoint Test A. See: Pinpoint Tests - SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate system to continue diagnostics. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1059 General Module: Diagnostic Trouble Code Tests and Associated Procedures DTC Index B1217 - B1318 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1060 DTC Index B1319 - B2494 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1061 DTC Index B2495 - C1962 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1062 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1063 General Module: Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC ELECTRONIC MODULE (GEM) Test A1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1064 Test A2-A3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1065 Test A4-A5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 1066 General Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) REMOVAL 1. NOTE: Prior to removal of the GEM, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the pin-type retainer and the lower shield. 3. Position the RH and LH carpet aside from the center tunnel. 4. Disconnect the GEM electrical connectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 1067 5. Remove the GEM 1 Pull back the insulation and remove the nuts. 2 Remove the GEM. INSTALLATION 1. To install, reverse the removal procedure. - Configure the GEM. Refer to Module Communications Network (Information Bus). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 1068 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 1075 Parking Assist Control Module: Service and Repair PARKING AID MODULE REMOVAL 1. Remove the right rear quarter trim panel. 2. Remove the parking aid module. 1 Remove the screws. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Application and ID Power Door Lock Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Passenger Side Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Passenger Side Front > Page 1087 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 1088 Seat Heater Control Module: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so may result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 1089 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so may result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 1090 - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Remove the front seat. 2. Remove the heated seat module. - Disconnect the electrical connector. - Using a small flat-blade screwdriver, release the locking tab and slide the module off the bracket. INSTALLATION WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar climate controlled heated power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition install the original part and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 1091 carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Install the heated seat module. - Slide the heated seat module down over the attachment bracket until the locking tab snaps into place. - Connect the electrical connector. 2. Install the front seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 1092 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 1096 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 1097 Sunroof / Moonroof Module: Service and Repair ROOF OPENING PANEL MODULE REMOVAL 1. Remove the headliner. 2. Remove the root opening panel module 1 Disconnect the electrical connector. 2 Remove the screw. 3 Remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair Technical Service Bulletin # 07S51S2 Date: 091009 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1107 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated April 10, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website. Owner names and addresses were made available April 30, 2007. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1108 NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles have been directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 07S51 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES If an ABS module needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Handling Allowance: An allowance of $1.00 per repair is being provided to cover the costs of locally obtained materials and XG-12 Electrical Grease. To claim the allowance, enter $1.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1109 ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1110 Parts will not be direct shipped for this program Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50376. Questions regarding parts should be directed to the Special Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected ABS Modules (Part number YL8Z-2C065-AA and YL8Z-2B373-BA) and the removed ABS connector are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector. During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number. If the ABS module is corroded, the ABS module and connector must be replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1111 A flow chart has been developed to help direct you to the proper repair. See Figure 1. Inspect Connector Seals INSPECTION 1. Disconnect the battery negative terminal. 2. NOTE: When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed. Disconnect the ABS module 25-pin connector by sliding the lock mechanism out (towards the passenger side of the vehicle) and pulling the connector off the module. 3. Disconnect the speed sensor harness, then remove the 2 harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection. 4. Inspect the top of the ABS module connector cover for 2 yellow "X" marks. ^ If 2 yellow "X" marks are present, perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. ^ If no yellow "X" marks are present, proceed to Step 5. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1112 5. Inspect the ABS module connector pins for corrosion. See Figure 2. ^ If corrosion is present, perform Labor Operation E - Install Pigtail, New ABS Module and Apply Electrical Grease. ^ If corrosion is not present, proceed to Step 6. 6. CAUTION: Do not cut any of the harness wires or the wire insulation when cutting off the tie strap. Remove the tie strap from the connector dress cover, then slide the cover off the connector. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1113 7. Verify the wire seals are present on the 4 heavier gauge wires. See Figure 4. 8. Verify the numbers 054" are stamped on the slide-lock end of the mat cover (wipe the mat cover clean if necessary to view). See Figure 5. NOTE: Mat covers with any other number will be missing plugs in the unused pin locations. 9. Perform Labor Operation C - Install Pigtail and Apply Electrical Grease if: ^ any seals are missing or, ^ if the number on the mat cover is not "054". 10. Perform Labor Operation D - Seat Connector and Apply Electrical Grease if: ^ Any of the 4 wire seals are not fully seated in the connector cavities. ^ Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. See Figure 4. 11. Perform Labor Operation A - Apply Electrical Grease if: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1114 ^ The module is not corroded. and ^ All seals are present. and ^ All seals are fully seated. and ^ The number on the mat cover is "054". LABOR OPERATION A - APPLY ELECTRICAL GREASE 1. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 6. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 6. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 3. Reconnect the battery negative terminal. LABOR OPERATION C - INSTALL PIGTAIL AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1115 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 7. 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 8. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 8. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1116 3. Strip approximately 6 mm (1/2 in) of insulation from each of the cut wires in the harness. See Figure 9. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1117 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 10. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 11. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1118 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 12. 8. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 13. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1119 connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 13. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 9. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 10. Reconnect the battery negative terminal. 11. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION D - SEAT CONNECTOR SEALS AND APPLY ELECTRICAL GREASE 1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool. DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal. See Figure 14. 2. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1120 b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 15. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 15. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 4. Reconnect the battery negative terminal. LABOR OPERATION E - INSTALL PIGTAIL, NEW ABS MODULE AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1121 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 16. PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 17. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 17. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1122 3. Strip approximately 6 mm (1/4 in) of insulation from each of the cut wires in the harness. See Figure 18. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1123 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 19. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 20. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1124 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 21. 8. Install a new ABS module. Perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. 9. Reconnect the battery negative terminal. 10. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION F - INSTALL NEW ABS MODULE AND APPLY ELECTRICAL GREASE NOTE: Module configuration or reprogramming is not required when installing a new ABS module. 1. Disconnect the 2-wire electrical connector at the ABS module. 2. Raise the vehicle on a hoist. 3. Remove the screws and the ABS module. 4. Position the new module and install the screws. Tighten the screws no more than 2 Nm (18 lb-in). 5. Lower the hoist. 6. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1125 ^ Use ONLY Motorcraft Electrical Grease XG-12. See Figure 22. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 22. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 7. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 8. Reconnect the 2-wire connector to the ABS module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1126 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1127 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1128 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1129 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1130 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1131 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA07V156000 > Mar > 07 > Recall 07V156000: ABS Module Connector Defect Electronic Brake Control Module: Recalls Recall 07V156000: ABS Module Connector Defect MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V156000 MFR'S REPORT DATE: March 30, 2007 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 446460 SUMMARY: On certain sport utility vehicles equipped with Antilock Brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short. CONSEQUENCE: An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated. Remedy: Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on April 23, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S51. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair Technical Service Bulletin # 07S51S2 Date: 091009 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1141 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated April 10, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website. Owner names and addresses were made available April 30, 2007. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1142 NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles have been directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 07S51 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES If an ABS module needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Handling Allowance: An allowance of $1.00 per repair is being provided to cover the costs of locally obtained materials and XG-12 Electrical Grease. To claim the allowance, enter $1.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1143 ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1144 Parts will not be direct shipped for this program Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50376. Questions regarding parts should be directed to the Special Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected ABS Modules (Part number YL8Z-2C065-AA and YL8Z-2B373-BA) and the removed ABS connector are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector. During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number. If the ABS module is corroded, the ABS module and connector must be replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1145 A flow chart has been developed to help direct you to the proper repair. See Figure 1. Inspect Connector Seals INSPECTION 1. Disconnect the battery negative terminal. 2. NOTE: When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed. Disconnect the ABS module 25-pin connector by sliding the lock mechanism out (towards the passenger side of the vehicle) and pulling the connector off the module. 3. Disconnect the speed sensor harness, then remove the 2 harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection. 4. Inspect the top of the ABS module connector cover for 2 yellow "X" marks. ^ If 2 yellow "X" marks are present, perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. ^ If no yellow "X" marks are present, proceed to Step 5. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1146 5. Inspect the ABS module connector pins for corrosion. See Figure 2. ^ If corrosion is present, perform Labor Operation E - Install Pigtail, New ABS Module and Apply Electrical Grease. ^ If corrosion is not present, proceed to Step 6. 6. CAUTION: Do not cut any of the harness wires or the wire insulation when cutting off the tie strap. Remove the tie strap from the connector dress cover, then slide the cover off the connector. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1147 7. Verify the wire seals are present on the 4 heavier gauge wires. See Figure 4. 8. Verify the numbers 054" are stamped on the slide-lock end of the mat cover (wipe the mat cover clean if necessary to view). See Figure 5. NOTE: Mat covers with any other number will be missing plugs in the unused pin locations. 9. Perform Labor Operation C - Install Pigtail and Apply Electrical Grease if: ^ any seals are missing or, ^ if the number on the mat cover is not "054". 10. Perform Labor Operation D - Seat Connector and Apply Electrical Grease if: ^ Any of the 4 wire seals are not fully seated in the connector cavities. ^ Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. See Figure 4. 11. Perform Labor Operation A - Apply Electrical Grease if: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1148 ^ The module is not corroded. and ^ All seals are present. and ^ All seals are fully seated. and ^ The number on the mat cover is "054". LABOR OPERATION A - APPLY ELECTRICAL GREASE 1. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 6. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 6. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 3. Reconnect the battery negative terminal. LABOR OPERATION C - INSTALL PIGTAIL AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1149 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 7. 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 8. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 8. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1150 3. Strip approximately 6 mm (1/2 in) of insulation from each of the cut wires in the harness. See Figure 9. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1151 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 10. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 11. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1152 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 12. 8. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 13. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1153 connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 13. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 9. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 10. Reconnect the battery negative terminal. 11. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION D - SEAT CONNECTOR SEALS AND APPLY ELECTRICAL GREASE 1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool. DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal. See Figure 14. 2. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1154 b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 15. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 15. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 4. Reconnect the battery negative terminal. LABOR OPERATION E - INSTALL PIGTAIL, NEW ABS MODULE AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1155 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 16. PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 17. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 17. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1156 3. Strip approximately 6 mm (1/4 in) of insulation from each of the cut wires in the harness. See Figure 18. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1157 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 19. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 20. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1158 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 21. 8. Install a new ABS module. Perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. 9. Reconnect the battery negative terminal. 10. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION F - INSTALL NEW ABS MODULE AND APPLY ELECTRICAL GREASE NOTE: Module configuration or reprogramming is not required when installing a new ABS module. 1. Disconnect the 2-wire electrical connector at the ABS module. 2. Raise the vehicle on a hoist. 3. Remove the screws and the ABS module. 4. Position the new module and install the screws. Tighten the screws no more than 2 Nm (18 lb-in). 5. Lower the hoist. 6. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1159 ^ Use ONLY Motorcraft Electrical Grease XG-12. See Figure 22. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 22. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 7. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 8. Reconnect the 2-wire connector to the ABS module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1160 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1161 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1162 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1163 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1164 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 1165 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA07V156000 > Mar > 07 > Recall 07V156000: ABS Module Connector Defect Electronic Brake Control Module: All Technical Service Bulletins Recall 07V156000: ABS Module Connector Defect MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V156000 MFR'S REPORT DATE: March 30, 2007 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 446460 SUMMARY: On certain sport utility vehicles equipped with Antilock Brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short. CONSEQUENCE: An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated. Remedy: Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on April 23, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S51. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1170 View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1171 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 1172 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery negative cable. 2. Disconnect the electrical connectors. 3. Raise and support the vehicle. 4. Remove the screws and the control module. 5. NOTE: The 4x2 module cannot be interchanged with the 4x4 module. The 4x4 module is interchangeable with the 4x2 module. To install. reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 1178 Radiator Cooling Fan Motor Relay: Locations Medium Speed Fan Control Relay Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 1179 View 151-12 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 1180 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 1183 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 1184 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 1185 Radiator Cooling Fan Motor Relay: Diagrams Medium Speed Fan Control Relay Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 1186 Radiator Cooling Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 1187 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1192 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1193 Blower Motor Relay: Description and Operation The blower motor relay supplies voltage to the blower motor and is activated when the key is ON and the function selector switch is in any position besides OFF. The blower motor relay is located under the instrument panel next to the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1194 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1195 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1199 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1200 Compressor Clutch Relay: Description and Operation The A/C compressor clutch relay supplies voltage to the A/C compressor clutch and is located in the Battery Junction Box (BJB). The Power Control Module (PCM) can interrupt the A/C compressor operation through the A/C compressor clutch relay under the following conditions: ^ during engine start-up ^ Wide Open Throttle (WOT) ^ low engine idle conditions ^ excessively high engine temperatures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1201 Compressor Clutch Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1202 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Testing and Inspection Instrument Panel Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Testing and Inspection > Page 1207 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 1212 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 1213 Daytime Running Lamp Control Unit: Service and Repair DAYTIME RUNNING LAMPS (DRL) MODULE REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and the DRL module. - Disconnect the electrical connectors. - Transfer parts as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 1217 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay Daytime Running Lamp Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 1220 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 1221 Daytime Running Lamp Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 1222 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1226 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1227 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1228 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Application and ID Headlamp Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1235 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1236 Headlamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1237 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1241 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1242 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1243 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Application and ID Interior Lighting Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1250 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1251 Parking Lamp Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1252 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 1257 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 1261 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Power Distribution Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Page 1265 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 1270 Relay Box: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 1271 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Pin Number and Connector View Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 1274 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 1275 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 1276 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 1277 Relay Box: Diagrams Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 1278 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 1281 Relay Box: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 1282 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1294 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1295 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1296 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1297 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1298 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 Body Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1303 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1304 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1308 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1309 Body Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1310 Body Control Module: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 59-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1311 59-2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1312 59-3 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque Based Electronic Throttle Control (ETC) Overview Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen II electronic throttle body (replaces throttle cable). Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by not coupling the throttle angle to pedal position, which enables various fuel economy schemes and technologies. Background "Why Torque Based ETC" Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM and low manifold vacuum) while still delivering the same torque requested by the driver. It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. It also enables many fuel economy/emission improvement technologies such as: - VCT (deliver same torque during transitions) - Continuously varying Transmission (CVT) - Hybrid Electric Vehicle (HEV) Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: - Eliminate cruise control actuators - Eliminate ISC Bypass actuator - Better airflow range - Packaging (no cable) Electronic Throttle Body The Gen II electronic throttle body (Figure 148) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from hard-stop angle). 4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75 degree). This hard stop is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use plate sealant. The hole in the plate is not required with ETB because the required idle airflow is provided by the plate angle, which also is the reason there is no IAC. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP assembly requires four wires. - 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 1316 position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2- (5 V Reference Voltage) - 2- (Signal Return "ground") - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A safe value will be substituted for a faulty signal if two out of the three signals are bad. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 1321 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 1322 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 1323 View 151-11 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 1326 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 1327 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accomodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 1330 Engine Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Powertrain Control Module (PCM) cover. 1 Loosen the bolt and disconnect the electrical connector. 2 Remove the nuts and the cover. 3. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1334 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 1337 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 1338 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 1339 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1344 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1345 Fuel Pump Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1346 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1350 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 1353 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 1354 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 1355 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1360 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1361 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 1362 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1367 Air Bag Control Module: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1370 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1371 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash ^ monitors the air bag Supplemental Restraint System (SRS) for faults ^ illuminates the air bag indicator if a fault is detected ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs) ^ signals the instrument cluster to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1372 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1375 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1376 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the instrument panel, disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1377 8. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 10. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1378 12. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 13. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 14. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1379 18. Disconnect the battery ground cable and wait at least one minute. 19. Position the carpet back at the right-hand side of the center tunnel area under the instrument panel. 20. Remove the right-hand side restraint control module (RCM) retaining bolts. 21. Remove the lower LH center instrument panel finish panel. 22. Position the carpet back at the left-hand side of the center tunnel area under the instrument panel. 23. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking dips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1380 INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1381 2. Tighten the right-hand side RCM bolts. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Reposition the carpet back at the right-hand side of the center tunnel area under the instrument panel. 4. Connect the RCM. 1 Tighten the bolt. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 5. Reposition the carpet back at the left-hand side of the center tunnel area under the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1382 6. Install the lower LH center instrument panel finish panel. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1383 12. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1384 onto the bracket under the seat. 16. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 17. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1385 19. Connect the passenger air bag module electrical connector. 20. Close the glove box. 21. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver air bag module electrical connector. 23. Install the steering wheel access cover. 24. Connect the battery ground cable. 25. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1386 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1387 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1388 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the instrument panel, disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1389 8. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 12. Connect the battery ground cable. 13. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1390 14. Disconnect the battery ground cable and wait at least one minute. 15. Position the carpet back at the right-hand side of the center tunnel area under the instrument panel. 16. Remove the right-hand side restraint control module (RCM) retaining bolts. 17. Remove the lower LH center instrument panel finish panel. 18. Position the carpet back at the left-hand side of the center tunnel area under the instrument panel. 19. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking dips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1391 INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1392 2. Tighten the right-hand side RCM bolts. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Reposition the carpet back at the right-hand side of the center tunnel area under the instrument panel. 4. Connect the RCM. 1 Tighten the bolt. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 5. Reposition the carpet back at the left-hand side of the center tunnel area under the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1393 6. Install the lower LH center instrument panel finish panel. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1394 12. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1395 15. Connect the passenger air bag module electrical connector. 16. Close the glove box. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the driver air bag module electrical connector. 19. Install the steering wheel access cover. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1396 Air Bag Control Module: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts according to this procedure. Weld nuts must be installed according to Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restr.Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts according to Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1397 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 1398 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1403 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay Starter Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 1406 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 1407 Starter Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 1408 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 1414 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 1415 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1420 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay Heated Glass Element Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 1423 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 1424 Heated Glass Element Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 1425 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 1435 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1444 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1445 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1446 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1447 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1453 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1454 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1455 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1456 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 1459 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 1460 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 1461 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1462 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR REMOVAL 1. NOTE: The rear bumper removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper removal for access. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1466 Parking Assist Switch: Service and Repair PARKING AID SWITCH REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the parking aid switch. 1 Disconnect the electrical connector. 2 Press the tabs. 3 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 1472 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Master Window/Door Lock/Unlock Switch View 151-34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Master Window/Door Lock/Unlock Switch > Page 1477 View 151-33 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 1480 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1483 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1484 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 1485 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1489 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1490 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1491 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1492 Exterior Rear View Mirror Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 1496 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 1497 Power Seat Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 1498 Power Seat Switch: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 1499 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 1500 Power Seat Switch: Service and Repair SEAT CONTROL SWITCH REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic toot must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Disconnect the battery ground cable. 2. Remove the seat control switch knob. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 1501 3. Remove the front seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - Disconnect the electrical connector(s). 4. Remove the seat control switch 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Side Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Side > Page 1506 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 1507 Seat Heater Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 1508 Seat Heater Switch: Service and Repair HEATED SEAT SWITCH REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Disconnect the battery ground cable. 2. Remove the seat control switch knob. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 1509 3. Remove the front seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - Disconnect the electrical connectors. 4. Release the locking tab and remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch > Page 1514 View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch > Page 1517 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1522 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1523 Brake Fluid Level Sensor/Switch: Description and Operation Brake Fluid Level Warning Switch The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the float and magnet actuates the reed switch that causes the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1527 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1528 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake warning indicator switch. ^ Remove the screws. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Removal Tips Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Removal Tips TSB 04-23-2 11/29/04 WHEEL SPEED SENSOR REMOVAL TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE When servicing the wheel speed sensors on a 2001-2005 Escape or 2005 Mariner and Escape Hybrid, care must be taken during removal to prevent damage. The wheel speed sensor wire has a body plug attached to it. This plug can be damaged if not removed correctly, such as removal for pinpoint testing. If the body plug is damaged, sensor replacement may be necessary even though the sensor is functional in all other respects. ACTION When removing the body plug, rotate the plug into a position which allows the use of a small screwdriver to release the tabs on the underside of the body plug. These two tabs are at right angles (directly above and below) to the sensor wire. See Figures 1 and 2 for reference. WARRANTY STATUS: Information Only Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Removal Tips > Page 1533 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1536 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1537 View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1538 View 151-28 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1541 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1542 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1543 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1544 Wheel Speed Sensor: Service and Repair Sensor-Front Removal and Installation 1. Remove the wheel and tire. 2. Detach the grommet from the body and pull the connector through the hole. 3. Disconnect the sensor wiring. 4. Detach the retainer. 5. Remove the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 1545 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Level Sensor: Customer Interest Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 1555 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Level Sensor: All Technical Service Bulletins Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 1561 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 1562 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 1563 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1568 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1569 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 1575 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 1578 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 1579 Brake Switch (Cruise Control): Service Precautions CAUTION: Initial installation of a deactivator switch allows for one adjustment. If additional adjustments are required, install a new switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 1580 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Remove the deactivator switch. 1 Disconnect the electrical connector. 2 Rotate counterclockwise 45 degrees and remove the deactivator switch. INSTALLATION CAUTION: Initial installation of a deactivator switch allows for one adjustment. If additional adjustments are required, install a new switch. 1. Release the plunger lock. ^ Turn the lock knob counterclockwise until the first click is felt. 2. Depress the brake pedal. 3. Install the deactivator switch. 1 Position the deactivator switch in the bracket and rotate clockwise 45 degrees. 2 Connect the electrical connector. 4. Slowly release the brake pedal and tug moderately once the pedal reaches the rest position. NOTE: There should be an extra click heard when tugging on the brake pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions Cruise Control Switch: Service Precautions WARNING: WHEN CARRYING A LIVE AIR BAG, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOUR BODY. IN THE UNLIKELY EVENT OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 1584 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the steering wheel cover. WARNING: WHEN CARRYING A LIVE AIR BAG, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOUR BODY. IN THE UNLIKELY EVENT OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Remove the steering wheel frame. 1 Remove the nuts. 2 Disconnect the ground wire. 3 Remove the steering wheel frame. 4. Disconnect the speed control switches electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 1585 5. Remove the speed control switches. 1 Remove the screws. 2 Remove the speed control switches. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sender ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1590 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1591 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1592 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. NOTE: The halfshaft is removed for clarity. Disconnect the oil pressure sender electrical connector. 3. Remove the oil pressure sender. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the blower motor switch knob. 3. Remove the blower motor switch. ^ Depress the locking tab. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C Clutch Cycling Pressure Switch View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C Clutch Cycling Pressure Switch > Page 1601 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 1604 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 1605 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). ^ The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). ^ When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the Powertrain Control Module (PCM) which energizes the A/C relay and supplies B+ voltage to the A/C clutch field coil. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. A/C Pressure Cut-Off Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the condenser to evaporator line. ^ A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, is used to monitor the compressor discharge pressure. ^ It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. ^ The A/C pressure cut-off switch has two sets of contacts. One electrical contact is normally closed. ^ When the compressor discharge pressure rises to approximately 3,103 kPa (450 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. The switch contains a second set of electrical contacts used for high-speed fan control. ^ When the compressor discharge pressure reaches approximately 2,241 kPa (325 psi), these contacts close and engage the high-speed fan control. ^ When the pressure drops to approximately 1,896 kPa (275 psi), the contacts again open and the high speed fan control is disengaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Cycling Switch REMOVAL 1. Remove the A/C cycling switch. 1 Disconnect the A/C cycling switch electrical connector. 2 Remove the A/C cycling switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch > Page 1608 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff Switch REMOVAL 1. Remove the pressure cut-off switch. 1 Disconnect the A/C pressure cut-off switch electrical connector. 2 Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 1613 Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 1614 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 1615 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH REMOVAL 1. Remove the instrument panel dimmer switch. 2. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Ajar Switch View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 1620 View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1623 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1627 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1628 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake warning indicator switch. ^ Remove the screws. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Transmission Range Sensor View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Transmission Range Sensor > Page 1634 View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range (TR) Sensor Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range (TR) Sensor > Page 1637 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1641 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1642 Brake Light Switch: Service and Repair BRAKE PEDAL POSITION (BPP) SWITCH REMOVAL 1. Remove the brake pedal position (BPP) switch. 1 Disconnect the electrical connector. 2 Rotate clockwise and remove the BPP switch. INSTALLATION NOTE: Initial installation of brake pedal position (BPP) switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. To unlock, rotate the lock knob counterclockwise to the stop. 2. With the engine running, fully depress and hold the brake pedal. 3. Install the brake pedal position (BPP) switch. 1 Position the BPP switch in the bracket and rotate counterclockwise. 2 Connect the electrical connector. 4. Slowly release the brake pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 1647 View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1650 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1654 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1655 Fog/Driving Lamp Switch: Service Precautions CAUTION: Do not use a screwdriver to remove fog lamp switch or damage to the finish panel may occur. Adding tape to the end of a thin tool will reduce marring to the finish panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1656 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REMOVAL 1. Disconnect the battery ground cable. CAUTION: Do not use a screwdriver to remove fog lamp switch or damage to the finish panel may occur. Adding tape to the end of a thin tool will reduce marring to the finish panel. 2. Use a thin tool to remove the fog lamp switch. 3. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1660 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1661 Hazard Warning Switch: Service and Repair Hazard Flasher Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Position the instrument panel center finish panel removal from the instrument panel. 3. Remove the hazard flasher switch. 1 Disconnect electrical connector. 2 Remove the hazard flasher switch. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-20 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1665 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1666 Headlamp Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1667 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1673 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1674 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1678 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1679 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1680 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Service and Repair Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position (CPP) electrical connector. 2. Remove the CPP locknut and the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1687 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1688 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1689 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 1693 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 1694 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1698 Fuel Tank Pressure Sensor: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the rear seat assembly. 3. Remove the fuel tank sending unit access cover. 4. Disconnect the fuel tank pressure sensor electrical connector. 5. Remove the fuel tank pressure sensor. ^ Disconnect the vapor tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1699 ^ Carry out a leak test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1703 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1704 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1709 Oxygen Sensor: Harness Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1710 View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Oxygen Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Oxygen Sensor: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1734 Oxygen Sensor: Application and ID In-Line Engines V-Engines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Remove the bolts and the exhaust manifold heat shield. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 1737 INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 1738 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the catalyst monitor sensor electrical connector. 2. Raise and support the vehicle. 3. Using the special tool, remove the catalyst monitor sensor. NOTE: If necessary, lubricate the catalyst monitor sensor with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the catalyst monitor sensor to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 1739 EGO Sensor Wrench Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1768 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1769 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1770 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1771 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1775 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1776 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1777 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1778 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1782 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1783 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1784 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1785 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1786 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1787 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1791 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1796 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1797 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1798 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 1799 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1804 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1805 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1809 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1813 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System The Inertia Fuel Shutoff (IFS) switch (Figure 73) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System > Page 1816 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System NATURAL GAS FUEL SYSTEM Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Reset Instructions 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. 4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking natural gas. WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE IFS SWITCH. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Page 1817 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Remove the cowl side trim panel. 1 Remove the pin-type retainers. 2 Remove the nut. 3 Remove the cowl side trim panel. 2. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Disconnect the connector. 2 Remove the screws and the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1821 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1822 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1823 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1824 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1829 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1830 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1831 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1835 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1836 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1837 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL 1. Disconnect the battery ground cable. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1845 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1846 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left > Page 1852 View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right > Page 1855 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 1858 Impact Sensor: Technician Safety Information WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 1859 Impact Sensor: Description and Operation WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. For this vehicle, the SRS employs three crash sensors. One of the sensors is integral to the RCM and is not serviceable separately. In addition, there are two side crash sensors located in the LH and RH B-pillars. The RCM is mounted on the center tunnel under the instrument panel. Mounting orientation is critical for correct operation of all crash sensors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1862 be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR, TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1863 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1864 8. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 10. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1865 12. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 14. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 18. Disconnect the battery ground cable and wait at least one minute. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1866 19. Remove the B-pillar trim panel. 20. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1867 seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side crash sensor. 1 Position the side crash sensor to the B-pillar. 2 Install the bolts. 3 Connect the side crash sensor electrical connector. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools still in place at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. Install the B-pillar trim panel. 6. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1868 8. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 10. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1869 11. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 12. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1870 15. Connect the passenger air bag module electrical connector. 16. Close the glove box. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the driver air bag module electrical connector. 19. Install the steering wheel access cover. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1871 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Check the restraint system for correct operation. Passenger Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1872 NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Open the glove box past its stops. 3. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1873 4. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. 5. Remove the steering wheel access cover. 6. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1874 8. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 9. Attach the restraint system diagnostic toot to the driver side air bag module floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1875 12. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 14. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 18. Disconnect the battery ground cable and wait at least one minute. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1876 19. Remove the B-pillar trim panel. 20. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1877 ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side crash sensor. 1 Position the side crash sensor to the B-pillar. 2 Install the bolts. 3 Connect the side crash sensor electrical connector. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools still in place at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. Install the B-pillar trim panel. 6. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1878 8. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1879 the bracket under the seat. 12. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1880 15. Connect the driver air bag module electrical connector. 16. Install the steering wheel access cover. 17. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the passenger air bag module electrical connector. 19. Close the glove box. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1881 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Check the restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1882 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts according to this procedure. Weld nuts must be installed according to Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts according to Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1883 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 1884 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash ^ monitors the air bag Supplemental Restraint System (SRS) for faults ^ illuminates the air bag indicator if a fault is detected ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs) ^ signals the instrument cluster to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt Buckle Switch: Customer Interest SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt Buckle Switch: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 1901 View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 1902 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Clutch Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Clutch Switch > Page 1908 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 1911 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL 1. Disconnect the battery ground cable. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1919 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1940 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1941 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1942 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1943 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1944 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1945 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1946 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1952 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1953 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1954 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1955 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1956 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1957 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine Shaft Speed (TSS) sensor bolt .................................................................................................................................................... 13 Nm (10 ft. lbs.) Output Shaft Speed (OSS) sensor bolt ..................................................................................................................................................... 13 Nm (10 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 1963 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Connector Output Shaft Speed (OSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 1966 Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor Connector Turbine Shaft Speed (TSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 1967 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 1968 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Remove the Output Shaft Speed (OSS) sensor. ^ Disconnect the OSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the OSS bore. 5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 1971 1. NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Install the OSS sensor. ^ Connect the OSS sensor electrical connector. 2. Install the splash shield. 3. Install the LH front wheel. 4. Lower vehicle. 5. Check the transmission fluid level, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 6. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 1972 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Place a drain pan beneath the Turbine Shaft Speed (TSS) sensor. 5. Remove the TSS sensor. ^ Disconnect the TSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the TSS sensor bore. 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 1973 1. NOTE: Apply a light coat of petroleum jelly to the O-ring seal before installation. Install the TSS sensor. ^ Connect the TSS electrical connector (white connector). 2. Remove the drain pan. 3. Install the splash shield. 4. Install the LH front wheel. 5. Lower the vehicle. 6. Check the transmission fluid level, add fluid as necessary using clean automatic transmission fluid. 7. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) bolt ............................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 1978 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the bolt and the VSS. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations View 151-19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 1983 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 1984 Heated Glass Element Switch: Service and Repair REAR WINDOW DEFROST SWITCH REMOVAL 1. Remove the audio unit. 2. Push outward on the rear window defrost switch to remove it from the instrument panel center finish panel. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side View 151-33 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side > Page 1989 View 151-35 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side > Page 1990 View 151-34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 1993 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 1994 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 1995 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 1998 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 1999 Master Window Control Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2000 Power Window Switch: Testing and Inspection Window Adjust Switch Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2001 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 2002 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH NOTE: The removal and installation procedures for all window control switches are similar. REMOVAL 1. Remove the front door trim panel or the rear door trim panel. 2. Release the locking clips and remove the window control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 2007 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 2008 Windshield Washer Switch: Service and Repair WINDSHIELD WIPER/WASHER SWITCH REMOVAL AND INSTALLATION 1. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. Remove the steering column shroud. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-20 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2012 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2013 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2014 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2015 Wiper Switch: Service and Repair WINDSHIELD WIPER/WASHER SWITCH REMOVAL AND INSTALLATION 1. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. Remove the steering column shroud. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics Alignment: By Symptom Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2025 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2026 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2027 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2028 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics Alignment: All Technical Service Bulletins Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2034 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2035 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2036 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 2037 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Front Position - Curb Caster .................................................................................................................................................. .................................................... 1.79° ± 1.00° Caster Split ............................................................... .................................................................................................................................... -1° to +1° Camber ................................................................................................................................................ .................................................. -0.48° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Total Toe ...................................................................................................................................................... .......................................... 0.08° ± 0.32° Ride Height ......................................................................... .......................................................................................................... 476.6 mm ± 20 mm Side-to-Side Lean ................................................................................................................................ .......................................... -10 mm to +10 mm Position - 8 gal. fill Caster .................................................................................................................................................. .................................................... 1.72° ± 1.00° Caster Split ............................................................... .................................................................................................................................... -1° to +1° Camber ................................................................................................................................................ .................................................. -0.48° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Total Toe ...................................................................................................................................................... ............................................ 0.08 ± 0.32° Ride Height ........................................................................ ........................................................................................................... 477.4 mm ± 20 mm Side-to-Side Lean ................................................................................................................................ .......................................... -10 mm to +10 mm Rear Position - Curb Camber ................................................................................................................................................ .................................................. -0.04° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Indiv. Toe ...................................................................................................................................................... ......................................... 0.04° ± 0.17° Ride Height .......................................................................... ............................................................................................................ 491 mm ± 20 mm Side-to-Side Lean ..................................................................................................................................................... ..................... -10 mm to +10 mm Clear Vision .................................................................................... ..................................................................................................................... 0 ± 3 Position - 8 gal. fill Camber ................................................................................................................................................ .................................................. -0.13° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Indiv. Toe ...................................................................................................................................................... ......................................... 0.04° ± 0.17° Ride Height .......................................................................... ............................................................................................................ 495 mm ± 20 mm Side-to-Side Lean ..................................................................................................................................................... ..................... -10 mm to +10 mm Clear Vision .................................................................................... ..................................................................................................................... 0 ± 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 2040 Alignment: Specifications Torque Specifications Front shock absorber upper mounting bracket nuts .................................................................................................................................. 80 Nm (59 ft. lbs.) Rear suspension trailing arm and bushing bolts ...................................................................................................................................... 115 Nm (41 ft. lbs.) Tie rod end jam nuts .................................................................................................................... ............................................................. 55 Nm (41 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2041 Alignment: Description and Operation Suspension System The front suspension system consists of the following components ^ strut and spring assembly upper mounting bracket ^ upper spring seat ^ wheel hub ^ lug bolts ^ front wheel bearing ^ front suspension lower arm ball joints ^ front wheel knuckle ^ front stabilizer bar and brackets ^ front suspension lower and mounting bolt bushing (horizontal) ^ strut and spring assembly ^ stabilizer control link The front strut and spring assemblies can be disassembled to install any of the new individual components. New LH or RH front strut and spring assemblies can be installed independently. The front suspension system can also be disassembled in order to install new: ^ front wheel knuckle ^ wheel hub ^ lug bolts ^ front wheel bearing ^ front suspension lower arms ^ front suspension lower arm mounting bolt bushings (horizontal) New front stabilizer bar components can be installed individually. The rear suspension system consists of the following components: ^ rear spring ^ rear shock absorber ^ rear wheel knuckle and bushing ^ lower lateral link ^ upper lateral link ^ bump stopper New LH and RH rear wheel knuckles can be installed individually. The rear suspension arm and bushings can be installed individually. Only toe can be adjusted on the rear suspension. Wheel Alignment Angles Camber Camber is the inward or outward tilting of the wheels at the top. When the wheel tilts out at the top, then the camber is positive (+). When the wheel tilts in at the top, then the camber is negative (-). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2042 Caster Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. Front caster should fall within specification when the front camber is adjusted. Toe Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in toward the front of the vehicle, toe is positive (+) (toe inch). When the wheels are turned out toward the front of the vehicle, toe is negative (-) (toe out). Toe is measured in degrees, from side to side, and totaled. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Raise and support the vehicle. 2. Remove the front shock absorber upper mounting bracket nuts. 3. Push the front shock absorber upper mounting bracket downward and turn it to the desired position to set camber and caster. Both camber and caster for front suspension are adjustable within a maximum of 30 minutes angle. 4. Tighten the front shock absorber upper mounting bracket nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2045 Alignment: Service and Repair Front Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and lock the steering wheel in position. 3. Check the toe settings. Follow the equipment manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie rod is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie rod threads. 6. Rotate the front wheel spindle tie rods. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2046 7. Tighten the nuts. 8. Install the clamp(s). 9. Recheck the toe settings. Follow the equipment manufacturer's instructions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2047 Alignment: Service and Repair Rear Toe Adjustment Rear Toe Adjustment 1. NOTE: Jounce the vehicle to make sure that the suspension is in its normal resting position. Check the toe setting using suitable wheel alignment equipment. 2. Loosen the LH and RH rear suspension trailing arm and bushing bolt. 3. Turn the LH and RH adjusting cams simultaneously until the toe is within specification. 4. Tighten the LH and RH rear suspension trailing arm and bushing bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2048 Alignment: Service and Repair Lean Correction Lean Correction NOTE: When installing a new coil spring, install a new one with the same part number and the same spring code. Refer to the Vehicle Certification (VC) Label on the driver side door. 1. Measure the distance from the wheelhouse opening to the center of the wheel and tire at the same point on both sides of the vehicle. 2. If the difference exceeds 10 mm (0.4 inch), a lean correction is necessary. Compare the original with a new coil spring. Note the difference. 3. Remove the higher side coil spring. 1 If the original coil spring exceeds the height of the new one by 10 mm (0.4 inch), install the new coil spring in the vehicle. 2 If the original coil spring is shorter than the new one by 10 mm (0.4 inch), remove the low side coil spring from the vehicle. 4. Compare all three coil springs and select the two most evenly matched for installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the air cleaner. 2. Remove the battery tray. 3. Remove the bolt and the intake pipe. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the front sponge seal of the intake pipe is seated on the shroud panel correctly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2062 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications 4-Cyl Firing Order: 1 3 4 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2066 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. ^ Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2074 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and with a twisting-pulling motion, disconnect the ignition wires from the spark plugs. CAUTION: Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. 2. Disconnect the ignition wires from the ignition coil and remove the wires. INSTALLATION 1. Connect the ignition wires to the correct ignition coil terminals. CAUTION: Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. NOTE: ^ Whenever an ignition wire is reinstalled or a new one is installed, apply Silicone Brake Caliper Grease and Dielectric compound to the interior surface of the ignition wire boot. ^ Before installing the ignition wires, inspect the ignition wires for any visible damage; install new ignition wires if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2075 2. Connect the ignition wires to the correct spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap Spark Plug Gap 0.048-0.052 inch (1.22-1.32 mm) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2079 Spark Plug: Service Precautions CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2080 Spark Plug: Application and ID Spark plug cylinders 1 and 3................................................................................................................ ....................................................................AZFS-32F Spark plug cylinders 2 and 4........................... .......................................................................................................................................................AZF S-32FE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2081 Spark Plug: Service and Repair REMOVAL CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. 1. Grasp the spark plug boot firmly and with a twisting-pulling motion remove the spark plug wires from the spark plug. 2. Remove the spark plugs. NOTE: ^ If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs can be used in any cylinder. ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs. INSTALLATION 1. Adjust the plug gap as necessary. NOTE: Clean the spark plugs with a wire brush or a professional spark plug cleaner (follow the manufacture's instructions). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2082 2. Install the spark plugs. NOTE: Apply Anti-Seize Lubricant to the lower three threads of the spark plugs. Do not allow lubricant to contaminate the spark plug electrodes or insulator tips. 3. Connect the spark plug wires to the spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2086 Compression Check: Testing and Inspection Compression Test Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the 0FF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2087 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve clearance - intake ........................................................................................................................................... 0.11-0.18 mm (0.004331-0.007087 in.) Valve clearance - exhaust .................................................................................................................................... 0.27-0.34 mm (0.0106299-0.0133858 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2091 Valve Clearance: Service and Repair Valve-Valve Clearance, Adjust Special Tool(s) Removal 1. Remove the timing belt. 2. Remove the camshaft alignment tool. 3. NOTE: Measure each valve's clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure each valves clearance and record its location. 4. Remove the camshafts. 5. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2092 Remove the valve tappets from the cylinder head. 6. NOTE: A midrange clearance is the most desirable: ^ intake: 0.15 mm (0.006 in.) ^ exhaust: 0.3 mm (0.012 in.) NOTE: Select tappets using this formula: tappet thickness = measured clearance plus the base tappet thickness minus most desirable thickness. Select tappets and mark installation location. Installation 1. NOTE: Lubricate the valve tappets with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Install the valve tappets. 2. Install the camshafts. 3. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet. 4. Install the camshaft alignment tool. 5. Install the timing belt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications Timing Belt: Specifications Upper timing belt cover bolts ............................................................................................................... ...................................................... 8 Nm (71 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2096 Timing Belt: Service and Repair Timing Belt Special Tool(s) Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet pipe. 3. Remove the spark plugs. 4. Disconnect the throttle cables. ^ If equipped, disconnect the speed control actuator cable. ^ Disconnect the accelerator cable. 5. Disconnect the catalyst monitor and heated oxygen sensor electrical connectors. Detach the electrical connectors from the bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2097 6. Remove the wiring harness anchors from the valve cover studs and position the wiring harness aside. 7. Remove the valve cover. 1 Remove the stud bolts. 2 Remove the bolts. 8. CAUTION: The valve cover sealing surfaces are soft materials. Do not use abrasive grinding discs to remove gasket material. Use only a plastic scraping tool. Do not scratch or gouge sealing surfaces or oil leaks can occur. Clean and inspect the sealing surfaces of the valve cover and cylinder head. Both surfaces must be clean and flat. 9. Remove the catalytic converter. 10. Remove the bolt and nut and position the coolant tube aside. 11. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching of the center cap, place face up when removed. Remove the wheel and tire assembly. 1 Remove the center cap. 2 Remove the wheel nuts. 3 Remove the wheel and tire assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2098 12. Remove the RH lower splash shield. 13. Rotate the crankshaft to just before top dead center (TDC) (No. 1 cylinder). 14. Remove the stud. 15. Install the special tool. 16. NOTE: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2099 Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder). 17. Loosen the water pump pulley bolts. 18. Loosen the crankshaft pulley bolt. 19. Rotate the tensioner and remove the accessory drive belt. 20. Remove the bolt and the crankshaft pulley. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2100 21. Remove the bolts and the lower timing belt cover. 22. Lower the vehicle. 23. Install the special tool. 24. Detach the ground strap. 25. Remove the nuts, the bolt and the engine mount upper bracket. 26. Remove the studs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2101 27. Detach the knock sensor electrical connector from the upper timing cover. 28. Remove the bolts and the upper timing cover. 29. Remove the water pump pulley. 30. Remove the accessory drive belt idler pulley. 31. NOTE: Installation of the alignment tool into the exhaust camshaft can require the camshafts to be rotated clockwise slightly. Install the special tool and align the camshafts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2102 32. Raise the vehicle. 33. Remove the bolts and the engine mount lower bracket. 34. Loosen the timing belt tensioner pulley and allow to slide down to the bottom of its travel. 35. CAUTION: If the camshaft timing belt is to be reused, mark the direction of the camshaft timing belt to rotation of camshaft prior to removal or premature wear or failure can occur. Slide the timing belt off of the camshaft and crankshaft sprockets. 36. Inspect the timing belt for wear. Install a new belt if necessary. Installation 1. NOTE: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg. ^ Remove the crankshaft pulley. 2. Lower the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2103 3. Confirm that the timing belt tensioner is installed correctly with the tab positioned in the slot in the inner timing cover. 4. Install the timing belt onto the timing belt sprockets. 5. Adjust the timing belt tensioner. 1 Using a 6 mm Allen wrench, rotate the adjuster counterclockwise and align the marks as shown. 2 Tighten the tensioner pulley bolt. 6. CAUTION: The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft can result. NOTE: Use an open-end wrench to keep each camshaft from rotating. If the timing sprockets were removed. tighten the camshaft timing sprocket bolts to specifications. 7. Raise the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2104 8. Install the front engine mount lower bracket. 9. Install the accessory drive belt idler pulley. 10. Install the water pump pulley. ^ Hand-tighten the bolts. 11. Lower the vehicle. 12. Position the upper timing belt cover and install the bolts. 13. Install the studs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2105 14. Connect the knock sensor electrical connector to the upper timing belt cover. 15. Install the engine mount upper bracket, the nuts and the bolt. 16. Attach the ground strap and install the nut. 17. Remove the special tool. 18. Raise the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2106 19. Position the lower timing belt cover and install the bolts. 20. Position the crankshaft pulley and install the bolt. ^ Hand-tighten the bolt. 21. Rotate the tensioner and install the accessory drive belt. 22. Tighten the crankshaft pulley bolt. 23. Tighten the water pump pulley bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2107 24. Position the RH lower splash shield and install the bolts 25. WARNING: Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions can result in personal injury. Clean the wheel hub mounting surface and the wheel pilot 26. Install the wheel and tire assembly 1 Position the wheel and tire assembly 2 Install the wheel nuts hand-tight 27. Remove the special tool. 28. Install the stud 29. Install the coolant tube. 30. Install the catalytic converter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2108 31. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in the sequence shown. 32. Install the center cap. 33. Remove the special tool. 34. Inspect the valve cover gasket. Install a new gasket, if necessary. 35. Position the valve cover. 1 Install the stud bolts. 2 Install the bolts. 36. Connect the wiring harness anchors to the valve cover studs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications > Page 2109 37. Attach the catalyst monitor and heated oxygen sensor electrical connectors to the bracket. Connect the electrical connectors. 38. Connect the throttle cables. ^ Connect the accelerator cable. ^ If equipped, connect the speed control actuator cable. 39. Install the spark plugs. 40. Install the air cleaner outlet pipe. 41. Connect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Without A/C Drive Belt: Locations Without A/C 2.0L Zetec without A/C 2.0L Zetec Without A/C Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Without A/C > Page 2114 Drive Belt: Locations With A/C 2.0L Zetec with A/C 2.0L Zetec With A/C Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2115 Drive Belt: Diagrams 2.0L Zetec Without A/C 2.0L Zetec With A/C Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Accessory Drive Inspection and Verification 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the mechanical concerns apply. 3. NOTE: Minor cracks in the V-grooved portion of the drive belt are considered normal and acceptable. If the drive belt has chunks missing from the ribs, a new drive belt should be installed. Install a new drive belt if any of the following conditions exist: rib chunk-out, severe glazing, frayed cords or other concerns. Inspect for drive belt cracking/chunking/wear. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Serpentine Drive Belt With Cracks Across Ribs V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) V-Ribbed Serpentine Drive Belt With Chunks of Rib Missing 4. If the concerns remain after inspection, determine the symptoms. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2118 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Part 1 Of 2 Part 2 Of 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2119 Drive Belt: Component Tests and General Diagnostics Belt Tensioner Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. Remove the belt in the area of the tensioner. 2. Rotate the 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 that there is tension on the belt tensioner spring. 3. If the tensioner meets the above criteria, proceed to test the tensioner dynamically. If the tensioner does not meet the above criteria, install a new tensioner. Belt Tensioner Dynamic The belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the belt tensioner movement. The belt tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can be checked by installing a new drive belt, and repeating the observation. 2. With the engine off, check routing of the drive belt. 3. Inspect the belt tensioner wear indicator to confirm the drive belt is within operating range. Install a new drive belt if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2120 Drive Belt: Service and Repair Accessory Drive Belt-2.0L Zetec Removal and Installation 1. Remove the right front wheel and tire. 2. Remove the bolts and the right front lower splash shield. 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the air cleaner. 2. Remove the battery tray. 3. Remove the bolt and the intake pipe. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the front sponge seal of the intake pipe is seated on the shroud panel correctly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions Evaporative Canister Filter: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions > Page 2132 Evaporative Canister Filter: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. 3. Disconnect the EVAP canister outlet tube. 4. Disconnect the canister vent solenoid electrical connector and the remote canister vent hose. 5. Remove the EVAP canister bracket assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions > Page 2133 6. Remove the remote canister vent hose. 7. Remove the dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out a leak test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL (R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Locations Fluid Filter - A/T: Locations Part 1 Of 7 Transmission Fluid Filter Location Filter is located at exploded view position number 8 internal. See Transmission Disassembly/Assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Locations > Page 2137 Special Tool Seal Removal Transmission Filter Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2142 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil filter ................................................................................................................................................ .................................................... 16 Nm (12 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Coolant tube bolt/nut ........................................................................................................................... ..................................................... 20 Nm (15 ft. lbs.) Coolant tube bracket bolt (oil cooler) ...................................................................................................................................................... 10 Nm (89 in. lbs.) Coolant tube stud ....................................................................................................... ............................................................................... 24 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2158 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2159 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2165 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2166 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2167 Heater Hose: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Disconnect the heater hose from the hose connection. 4. Remove the RH front wheel. 5. Disconnect the heater hose from the hose connection. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the hoses with Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Page 2171 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator line contains high-pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube assembly is attached to the A/C compressor with O-ring seals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Page 2172 Hose/Line HVAC: Service and Repair REMOVAL 1. Remove the A/C pressure cut-off switch. 2. Remove the evaporator core orifice. 3. Disconnect the condenser to evaporator line from the A/C evaporator core. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 4. Remove the evaporator line support nut and remove the line from the A/C evaporator core. 5. Remove the front bumper cover. 6. Remove the nut and disconnect the condenser to evaporator line from the A/C condenser core and remove the condenser to evaporator line. CAUTION: Plug all ports to prevent contamination from dirt or moisture. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power steering pressure hose to steering gear fitting ..................................................................................................................... 28-33 Nm (21-25 ft. lbs.) Power steering pressure line-to-pump fitting ........................................................................................................................................... 65 Nm (48 ft. lbs.) Power steering pressure line bracket-to-engine bolt ................................................................................................................................ 25 Nm (18 ft. lbs.) Power steering pressure and return line retainer plate-to-gear bolt .......................................................................................................... 25 Nm (18 ft. lbs.) Power steering pressure line bracket-to-gear bolt ................................................................................................................................ 10 Nm (89 inch lbs.) Power steering return line bracket-to-gear bolt .................................................................................................................................... 10 Nm (89 inch lbs.) Power steering pressure line bracket-to-lifting eye bolt ....................................................................................................................... 10 Nm (89 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Special Tools Special Tool(s) Removal 1. Raise and support the vehicle. 2. NOTE: Drain the excess power steering fluid into a suitable drain pan. Disconnect the power steering pressure line from the power steering pump. 3. Lower the vehicle. 4. NOTE: Do not drop the O-ring seals. Disconnect the power steering pressure and return lines. 1 Remove the bolt. 2 Disconnect the power steering pressure and return lines. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2178 5. Remove the power steering pressure line bracket bolt to the steering gear. 6. Remove the power steering pressure line bracket bolt to the engine lifting hook. 7. Remove the power steering pressure line bracket to engine bolt and the power steering pressure line. Installation 1. Using the special tool, install a new seal on the power steering pressure line fitting. ^ Remove and discard the original seal. ^ Stretch the seal over the special tool and slide it onto the tube nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2179 2. Install the power steering pressure line bracket to engine bolt. 3. Install the power steering pressure line bracket bolt to the engine lifting hook. 4. Install the power steering pressure line bracket bolt to the steering gear. 5. NOTE: Make sure the O-ring seals are on the power steering pressure and return lines. Connect the power steering pressure and return lines to the steering gear and install the bolt. 6. Raise the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2180 7. Connect the power steering pressure line to the power steering pump. 8. Lower the vehicle. 9. Fill, bleed and leak check the power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2181 Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Removal and Installation 1. NOTE: Drain the excess power steering fluid into a suitable drain pan. NOTE: Make sure not to drop the O-ring seals. Disconnect the power steering pressure and return lines. 1 Remove the bolt. 2 Disconnect the power steering pressure and return lines. 2. Remove the power steering return line bracket-to-gear bolt. 3. Release the clamp and remove the power steering return line. 4. NOTE: Make sure the O-ring seals are on the power steering pressure and return lines. To install, reverse the removal procedure. ^ Fill, bleed and leak check the power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the line on the reservoir. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 2187 Brake Fluid: Fluid Type Specifications Fluid Type ......................................................................................................................................... High Performance DOT 3 Motor Vehicle Brake Fluid Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Clutch Fluid Clutch Fluid Fill to the line on the reservoir. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 2192 Clutch Fluid: Fluid Type Specifications Clutch Fluid Clutch Fluid High Performance DOT 3 Motor Vehicle Brake Fluid. The hydraulic clutch system uses the same reservoir as the hydraulic brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info Coolant: Technical Service Bulletins Cooling System - Premium Gold Coolant Service Info Article No. 02-23-7 11/25/02 COOLING SYSTEM - MOTORCRAFT PREMIUM GOLD ENGINE COOLANT - SERVICE TIPS FORD: 2002-2003 ESCORT ZX2, FOCUS, MUSTANG, TAURUS, THUNDERBIRD 2003 CROWN VICTORIA 2002 EXCURSION 2002-2003 E SERIES, ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2003 EXPEDITION, WINDSTAR 2002-2003 F-650, F-750 LINCOLN: 2002 CONTINENTAL 2002-2003 LS 2003 TOWN CAR 2002-2003 BLACKWOOD 2003 AVIATOR, NAVIGATOR MERCURY: 2002-2003 SABLE 2003 GRAND MARQUIS 2002-2003 MOUNTAINEER Article 02-17-7 is being republished in its entirety to update the text and part numbers. ISSUE A new, extended-life engine coolant, yellow-colored Motorcraft Premium Gold Engine Coolant, meeting Ford Specification WSS-M97B51-A1, service part numbers VC-7-A and VC-7-C (for use in the U.S., except California and Oregon) and VC-7-B (for use only in California and Oregon as it contains a bittering agent), has been equipped in all of the vehicles noted above. The initial-fill life for this coolant is 100,000 miles/5 years. Due to variations in water quality, the replacement interval is 50,000 miles/3 years. ACTION Any time the addition of coolant or a coolant change-out is required, USE ONLY THE TYPE OF ENGINE COOLANT WITH WHICH THE VEHICLE WAS ORIGINALLY EQUIPPED. DO NOT MIX COOLANT TYPES. To determine the type of coolant required, check the color of coolant in the coolant reservoir of the vehicle or refer to the applicable vehicle's Owner's Guide or Workshop Manual for service parts and specification information. SERVICE INFORMATION Except for heavy-duty vehicles equipped with the Caterpillar 3126E engine, the use of a supplemental coolant additive (SCA) such as Motorcraft Heavy-Duty Cooling System Additive, service part number FW-16, is not required in conjunction with this coolant. Testing is currently underway to determine the backward compatibility of the Motorcraft Premium Gold Engine Coolant in vehicles equipped with the green-colored Motorcraft Premium Engine Coolant, service part numbers VC-4-A, VC-4-B, and VC-5. Until the final test results are available, vehicles should ONLY be serviced with type of coolant with which they were originally equipped. Please note that Motorcraft Premium Gold Engine Coolant is not compatible with any orange-colored, extended-life engine coolants such as Motorcraft Specialty Orange Engine Coolant, service part numbers VC-2 and VC-3. DO NOT MIX COOLANT TYPES. USE ONLY THE TYPE OF COOLANT WITH WHICH THE VEHICLE WAS EQUIPPED. Failure to follow these guidelines may result in degradation of corrosion protection and potential engine damage. Coolant Discoloration: The current Motorcraft Cooling System Stop Leak Pellets, service part number VC-6, used in both Production and Service, cause the yellow-colored Motorcraft Premium Gold Engine Coolant to change color ranging from a light golden brown to dark brown, depending upon the amount of pellet Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2197 material in the coolant reservoir. This discoloration does not adversely affect the coolant or the vehicle's cooling system components. No repairs are required for this condition. To avoid confusion with regard to coolant contamination, a new formulation of stop leak pellets will be implemented in Production and Service in the near future. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-17-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Coolant: Pressure, Vacuum and Temperature Specifications Cooling System Pressure Test Specification Radiator ............................................................................................................................................... .................................................... 138 kPa (20 psi) Radiator Cap Pressure Test Specification Radiator cap ..................................................................................................................................................... 110 + 14 kPa - 21 kPa (16 + 2 psi - 3 psi) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2200 Coolant: Capacity Specifications Fluid Capacity (Manual trans) .............................................................................................................. .............................................................. 7.0L (7.4 qt) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2201 Coolant: Fluid Type Specifications Coolant Types Caution: Do not mix coolant types. Motorcraft Premium Engine Coolant ......................................................... VC-4-A (in Oregon VC-5, in Canada CXC-10) ESE-M97B44-A (green color) Motorcraft Premium Gold Engine Coolant ...................................................................... VC-7-A (in Oregon VC-7-B) WSS-M97H51-A11 (yellow color) Motorcraft Premium Cooling System Flush ......................................................................................................................................... VC-1 ESR-M14F7-A Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications Differential Fluid - A/T: Specifications Ford Part Name - MERCON(R) V Automatic Transmission Fluid Ford Part Number - XT-5-QM Ford Specification - MERCON(R) V Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 2209 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 2210 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ............................................................... 10 Qt (9.5L) Note: Approximately Dry Fill Capacity Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2213 Fluid - A/T: Fluid Type Specifications Ford Part Name - MERCON(R) V Automatic Transmission Fluid Ford Part Number - XT-5-QM Ford Specification - MERCON(R) V Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Material Removal 1. Raise and support the vehicle. 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. Installation 1. 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 D8AZ-19554-A or XW7Z-19554-AA or equivalent meeting Ford specification WSK-M2G350-A2. 2. Lower the vehicle 3. Add 3.7 liters (3.9 quarts) of MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 4. Start the engine and run through all gears for a total of five minutes at idle. Turn off the engine. 5. Repeat the previous steps to help flush fluid from the torque converter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 2216 Fluid - A/T: Service and Repair Check Fluid Level and Condition Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and the outside temperature is above 10°C (50°F). NOTE: Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (20 miles). If your vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather, or while pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. Under normal circumstances, there is no need to check the fluid level of the transaxle, since the vehicle does not use up transmission fluid. However, if the transaxle is not working correctly, for instance, the transaxle may slip or shift slowly, or there may be some sign of fluid leakage, the fluid level should be checked. Fluid Level Check 1. Drive the vehicle 30 km (20 miles) or until the vehicle reaches normal operating temperatures. 2. Park the vehicle on a level surface and engage the parking brake. 3. With your foot on the brake, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 4. Place the range selector in P (park) and leave the engine running. 5. Remove the fluid level indicator and wipe it clean with a clean cloth. 6. Install the fluid level indicator, making sure that it is fully seated in the filler tube. 7. Remove the fluid level indicator. The fluid should be in the designated areas for normal and room temperature. Low Fluid Level Do not drive the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator and the outside temperature is above 10°C (50°F). High Fluid Level Fluid levels above the safe range can result in transmission failure. An overfill condition of transmission fluid can cause shift or engagement concerns, or possible damage. High fluid levels can cause an overheating condition. See the previous note. Adding Fluid CAUTION: Use of a non-approved automatic transmission fluid can cause internal transmission component damage. An overfill condition of transmission fluid can cause shift or engagement concerns, or possible damage. Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the fluid level indicator. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 2217 If necessary, add fluid in 250 ml (1/2 pint) increments through the filler tube until the level is correct. If an overfill condition occurs, excess fluid should be removed by a qualified technician. Fluid Condition Check NOTE: Evidence of fluid contamination, breakdown, or incorrect fluid can cause poor shift quality. If the transmission fluid condition is suspect, drain the transaxle and replace the fluid with MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. ^ Make the normal fluid level check as described in, Fluid Level Check. ^ Observe the color and odor of the fluid. It should be red, not brown or black. Odor can indicate an overheating condition or clutch disc or band failure. ^ Use a clean, lint-free cloth and wipe the fluid level indicator. Examine the stain for evidence of solid particles and signs of antifreeze (gum or varnish on the fluid level indicator). If particles are present in the fluid or there is evidence of contamination, the transaxle drain plug should be removed and a sample of the fluid filtered through a paper filter and examined. If transaxle failure is confirmed by further evidence of coolant or excessive particles in the fluid, the transaxle must be completely cleaned and repaired. This includes cleaning and flushing the torque converter and transaxle cooling system. During disassembly and assembly all overhaul checks and adjustments of clearances and end play must be made. After repairing the transaxle, all diagnostic tests and adjustments listed in the diagnosis must be completed to make sure that the problem has been eliminated. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.8 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2222 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type Type ..................................................................................................................................................... .................. Motorcraft SAE 75W-90 Gear Oil GL-4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications Differential Oil Capacity Refill...................................................................................................................................................... ............................................... 1.4 Liters (2.95 Pints) Fill the rear axle 3-5 mm (1/8-3/16 inch) from the bottom of filler hole. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ........................................................... 4.25L (4.5 Qt) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2230 Engine Oil: Fluid Type Specifications Engine Oil .............................................................................................................................. Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2235 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid capacity .............................................................................................................................................................. 1.9 Liters (2.0 quarts) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 2238 Power Steering Fluid: Fluid Type Specifications Premium Power Steering Fluid F7AZ-3F823-BA ................................................................................................................................................ MERCON Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refregerant Capacity Refregerant Capacity 1 lbs 14 oz (850 kg) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2243 Refrigerant: Fluid Type Specifications A/C Refrigerant A/C Refrigerant R-134a Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2244 Refrigerant: Service Precautions CAUTION: ^ Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. 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. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. ^ If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection Refrigerant: Testing and Inspection Electronic Leak Detection Refrigerent Leak Detector SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. 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. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow instructions included with leak detector for handling and operation techniques. NOTE: System pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 2. If a leak is found, recover the refrigerant and repair the system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 2247 Refrigerant: Testing and Inspection Tracer Dye Leak Detection Special Tool(s) SPECIAL TOOL(S) NOTE: Ford Motor Company vehicles are produced with R-134a Leak Tracer Dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. 1. Check for leaks using a 120-watt UV spot lamp. 2. Scan all components, fittings and lines of the A/C system. 3. After the leak is repaired, remove any traces of leak dye with a general purpose oil solvent. 4. Verify the repair by operating the system for a short time and inspecting with the UV spot lamp. Tracer Dye Injection NOTE: System pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 1. Install the Manifold Gauge Set or a recovery station. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 2248 2. Turn the valve on the fluorescent tracer dye injector all the way to the left to close the valve. 3. Fill the reservoir with 7 ml (0.25 ounce) of R-134a Fluorescent Tracer Dye 164-R3712. 4. Install the injector between the low-side quick disconnect and the vehicle low-pressure service gauge port valve. 5. Open all quick disconnect valves and charge the refrigerant system. 6. When system charging is complete, recover the refrigerant from the dye injector. 7. Remove the dye injector from the low-side quick disconnect valve. NOTE: Only connect the dye-injector to the Manifold Gauge Set or the charging/recovery station when dye is to be injected. The dye injector has a one-way check valve that will prevent system refrigerant recovery and evacuation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery Refrigerant: Service and Repair Discharging and Recovery Special Tool(s) SPECIAL TOOL(S) 1. Prior to recovering or charging the refrigerant system, you must verify the purity of the refrigerant. 2. Connect the R-134a A/C Refrigerant Center to the low and high pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 6. If the system pressure rises, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs, then evacuate and recharge the A/C system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 2251 Refrigerant: Service and Repair Identifying Refrigerants Delux A/C Refrigerant Analyzer SPECIAL TOOL(S) 1. Follow the instructions included with the refrigerant analyzer to obtain the sample for testing. NOTE: Prior to recovering or charging the refrigerant system, you must use an A/C refrigerant analyzer to identify gas samples taken directly from the refrigeration system or storage containers. 2. The analyzer will display one of the following: ^ A green "PASS" Light Emitting Diode (LED) will light if the purity of the R-134, R-12 or the R-22 is better than 98% by weight. ^ A red "FAIL" LED will light if the purity of the gases does not meet the 98% purity standard. ^ A red "FAIL" LED and "HYDROCARBON" light will illuminate and a horn will sound if a hydrocarbon is detected above 5%. This will alert the user of potential hazards. 3. If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 2252 Refrigerant: Service and Repair Handling of Contaminated Refrigerants 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. ^ This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. ^ If this equipment is not available, contact an A/C service facility in your area with the correct equipment to carry out this service. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. 2. Determine and correct the cause of the customer's initial concern. 3. Remove the suction accumulator/drier. NOTE: ^ Residual refrigerant oil in the suction accumulator/drier must be drained and measured for correct oil system matching. ^ The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. 4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8. Dispose of contaminated refrigerant according to all federal, state and local regulations. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 2253 Refrigerant: Service and Repair Air Conditioning (A/C) System Evacuation and Charging Special Tool(s) SPECIAL TOOL(S) 1. Prior to charging the refrigerant system, you must verify the purity of the refrigerant. 2. Connect the R-134a A/C Refrigerant Center to the low and high pressure service gauge port valves. NOTE: Ford Motor Company recommends use of a charging station to carry out evacuation and charging of the refrigerant system. If a charging station is not available, system charging may be accomplished using a separate vacuum pump, charging cylinder, and manifold gauge set. 3. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) (vacuum) and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 4. Turn off the evacuation pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leaks, and evacuate the system again. 5. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. 6. Charge the system with the specified weight of refrigerant and refrigerant oil. 7. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the suction pressure drops to approximately 207 kPa (30 psi), close the charging hose valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2254 Refrigerant: Tools and Equipment Refrigerent Leak Detector Special Tool(s) Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2255 Delux A/C Refrigerant Analyzer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity Refrigerant Oil Capacity 9 oz (266 ml) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2260 Refrigerant Oil: Fluid Type Specifications A/C Oil A/C Oil PAG Refrigerant Compressor Oil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2261 Refrigerant Oil: Service Precautions CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2262 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDITION CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. ^ If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. ^ Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2263 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: ^ installation of a new A/C evaporator core orifice ^ installation of a new A/C compressor pressure relief valve ^ installation of a new refrigerant line ^ repair of an O-ring seal leak ^ repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Washer Fluid > Component Information > Specifications > Capacity Specifications Washer Fluid: Capacity Specifications Windshield Washer Fluid Windshield Washer Fluid 2.7 qts (2.6L) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fluids > Washer Fluid > Component Information > Specifications > Capacity Specifications > Page 2268 Washer Fluid: Fluid Type Specifications Windshield Washer Fluid Windshield Washer Fluid Type Motorcraft Premium Windshield Washer Fluid Concentrate Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel cylinder bleeder screws ............................................................................................................ .................................................... 8 Nm (71 inch lbs.) Bleeder screws ................................................ ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System Brake Bleeding: Service and Repair Bleeding - System Brake System Bleeding Special Tool(s) Anti-Lock Brakes Bleed NOTE: Bleeding the Hydraulic Control Unit (HCU) is required only when removing or installing the HCU or master cylinder, or opening the lines to the HCU. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the diagnostic tool. 2. Access the SYSTEM BLEED FUNCTION. Go to the Tool Tab-Chassis-Braking-ABS Service Bleed and follow the directions on the diagnostic tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of two diagnostic tool cycles and two manual bleed cycles. Manual Bleed Brake system WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. (let medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system alter it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel then to the RH front wheel and ending with the LH front wheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2274 Rear drum brakes 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 5. Loosen the bleeder screw until fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw. 6. Repeat Steps 4 and 5 until clear, bubble-free brake fluid flows. 7. Tighten the wheel cylinder bleeder screw. 8. Continue bleeding the rest of the system. Front disc brakes 9. Attach a rubber drain hose to the front disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 10. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 11. Loosen the front disc brake caliper bleeder screw until fluid flow stops. Maintain pressure on the brake pedal and tighten the front disc brake caliper bleeder screw. 12. Repeat Steps 10 and 11 until clear, bubble-free fluid flows. 13. Tighten the front disc brake caliper bleeder screw. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2275 14. Fill the brake master cylinder reservoir and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Gravity Bleed Brake system 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel, then to the RH front wheel and ending with the LH front wheel. Rear drum brakes 3. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Loosen the rear wheel cylinder bleeder screw and leave open until clear, bubble-free brake fluid flows. 4. Tighten the wheel cylinder bleeder screw. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2276 Front disc brakes 5. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Open the front disc brake caliper bleeder screw. Leave open until clear bubble-free brake fluid flows. 6. Tighten the front disc brake caliper bleeder screw. 7. Fill the brake master cylinder reservoir with fluid and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Brake System Pressure Bleeding Special Tool(s) WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2277 with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Clean the outside of the brake master cylinder reservoir. 2. Remove the reservoir cap and fill the brake master cylinder reservoir with brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 3. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install Brake Bleeder to the brake master cylinder reservoir, and attach the Brake Bleeder tank hose to the fitting on the adapter. 4. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 5. Open the valve on the Brake Bleeder tank. 6. Loosen the bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close the bleeder screw and remove the rubber hose. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2278 7. Tighten the wheel cylinder bleeder screw. 8. Continue bleeding the rest of the system, going in order from the LH rear wheel to the RH front wheel, ending with the LH front wheel. 9. Close the Brake Bleeder tank valve and remove the tank hose from the adapter, and remove the adapter. 10. Fill the brake master cylinder reservoir and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2279 Brake Bleeding: Service and Repair Bleeding - Components Component Bleeding Brake Master Cylinder-Bench Bleed WARNING: Use of any other than the approved DOT 3 brake will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed air may enter the system causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Support the brake master cylinder body in a soft jaw vise 2. Remove the master cylinder cap and install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir 3. NOTE: If equipped with a manual transmission plug the master cylinder feed port Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2280 Fill the brake master cylinder reservoir with High Performance DOT 3 brake fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A DOT 3 4. Slowly depress the primary piston until bubble -free brake fluid flows from both brake hoses 5. Remove the brake hoses from the master cylinder. 6. Install plugs in the front and rear brake outlet port. 7. Install the reservoir cap and install the brake master cylinder in the vehicle. ^ Remove the master cylinder outlet port plugs before installing the lines Brake Master Cylinder-In-Vehicle Bleed WARNING: Use of any other than the approved DOT 3 brake will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Disconnect the brake outlet lines from the brake master cylinder and cap the lines. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 2281 2. Install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 4. Have an assistant pump the brake pedal until clear, bubble-free brake fluid flows from both brake hoses. 5. Remove the short brake hoses and install the brake outlet lines. 6. Bleed the hydraulic brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2287 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2288 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2289 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2290 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2291 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2292 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2298 Fuse: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2299 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2302 Fuse: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2303 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2308 Fuse Block: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2309 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2312 Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2313 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2314 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2315 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2318 Fuse Block: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2319 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2324 Relay Box: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2325 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Pin Number and Connector View Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2328 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2329 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2330 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2331 Relay Box: Diagrams Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Central Junction Box > Page 2332 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2335 Relay Box: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2336 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) (Figure 17) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 18). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Malfunction Indicator Lamp (MIL) CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. - Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury. CAUTION: The service jack provided with the vehicle is only intended to be used in an emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle. Jacking points - Front Jacking Points - Front 1. The front jacking point is at the bolt head of the lower control arm. Jacking points - Rear Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Lifting Points Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2348 Lifting Points 1. CAUTION: Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. The lifting points are part of the uni-body structure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications Tires: Mechanical Specifications Tire Runout Specifications Type Wheel Aluminum Max. Radial Runout ............................................................................................................................. .................................... 1.5 mm (0.06 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Type Wheel Steel Max. Radial Runout ............................................................................................................................. .................................... 1.5 mm (0.06 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications > Page 2353 Tires: Pressure, Vacuum and Temperature Specifications Tire Inflation Tires ................................................................................................................................ See safety certification sticker located on the driver door jamb. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Specifications Wheels: Specifications Wheel Rim Runout Type Wheel Aluminum Max. Radial Runout ............................................................................................................................. ..................................... 1.5 mm (006 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Type Wheel Steel Max. Radial Runout ............................................................................................................................. ..................................... 1.5 mm (006 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Specifications > Page 2357 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise the wheel integrity. Install a new wheel. Straightening Wheels, Rims or Components 1. NOTE: Do not heat wheels in an attempt to soften them for straightening to repair damage. The special alloy used in these wheels is heat-treated. Uncontrolled heating from welding affects the properties of the material. Do not weld the wheels for any reason. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection NOTE: The wheel bearings are not adjustable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2363 Removal NOTE: Install a new wheel bearing when the wheel hub is removed. All vehicles 1. Remove the brake disc. 2. Remove the wheel hub nut. 3. Remove the tie rod end nut. 1 Remove the cotter pin. 2 Remove the nut. 4. Using the special tool, separate the tie rod end from the knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2364 Vehicles with ABS 5. Remove the bolt and position the anti-lock brake sensor aside. All vehicles 6. Separate the lower ball joint from the wheel knuckle. 1 Remove the pinch bolt. 2 Separate the lower ball joint from the wheel knuckle. 7. Using the special tool, separate the halfshaft from the wheel knuckle. ^ Position the halfshaft aside and support. 8. Remove the wheel knuckle. 1 Remove the strut-to-wheel knuckle bolts. 2 Remove the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2365 9. Using the special tool, press the wheel hub from the wheel bearing and knuckle. 10. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 11. Remove the snap ring. 12. Using the special tools, press the outer wheel bearing race from the wheel knuckle. NOTE: The brake disc shield is pressed on. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2366 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2367 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. 1 Position the wheel knuckle. 2 Install the strut-to-wheel knuckle bolts. 6. Using the special tool, insert the halfshaft into the wheel hub. 7. Install the pinch bolt into the wheel knuckle. ^ Position and align the ball joint stud into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2368 Vehicles with ABS 8. Install the anti-lock brake sensor and tighten the bolt. All vehicles 9. Install the tie rod end into the wheel knuckle. 1 Install the tie rod end nut. 2 Install a new cotter pin. 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2369 Wheel Bearing: Service and Repair Rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2370 Special Tool(s) Removal 1. Remove the brake drum. 2. NOTE: If equipped, remove the ABS sensor ring. Remove the wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2371 3. Using the special tools, remove the wheel hub. 4. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 5. Remove the snap ring. 6. Using the special tools, remove the wheel bearing outer race from the wheel knuckle. Installation 1. Using the special tools, install the wheel bearing into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2372 2. Install the snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. 4. NOTE: If equipped, install the ABS sensor ring. Install the wheel hub nut. 5. Install the brake drum. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel hub nut ..................................................................................................................................... .................................................. 290 Nm (214 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel nuts (all wheels) ....................................................................................................................... .................................................... 133 Nm (98 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal and Installation 1. Remove the front wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2382 Wheel Fastener: Service and Repair Rear Removal and Installation 1. Remove the wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. - Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury. CAUTION: The service jack provided with the vehicle is only intended to be used in an emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle. Jacking points - Front Jacking Points - Front 1. The front jacking point is at the bolt head of the lower control arm. Jacking points - Rear Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Lifting Points Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2386 Lifting Points 1. CAUTION: Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. The lifting points are part of the uni-body structure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded. The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A intake phase shifting system will move the intake cam in the advance direction. The other two possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module (PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems have the added benefit of improve torque. In addition a VCT system will eliminate the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Increased vehicle reliability is achieved with the elimination of the EGR system. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control module) with crankshaft positioning information in 10 degree increments (Figure 130). 1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant temperature), CMP, TP (throttle position), MAF (Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. 5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear piston motion to a rotational motion that advances or retards the camshaft. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2393 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty near 50%. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The VCT unit assembly (Figure 132) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, a pressure differential occurs forcing the piston to move. This movement is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2397 Compression Check: Testing and Inspection Compression Test Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the 0FF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2398 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft bearing cap bolts Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolts ...................................................................................................................... ...................................................... 68 Nm (50 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Theoretical valve lift @ 0 lash Intake ................................................................................................................................................... ................................... 09.254 mm (0.3643 in.) Exhaust ..................................................................... ................................................................................................................ 08.6 mm (0.33858 in.) Lobe lift Intake ................................................................................................................................................... ......................................... 8.9 mm (0.3504 in.) Exhaust ..................................................................... .................................................................................................................... 8.7 mm (0.3425 in.) Journal diameter ............................................................................................................................................... 25.960 25.980 mm (1.0221 - 1.0227 in.) End play ........................................................................................................................................................... 0.080 - 0.220 mm (0.00315 - 0.00866 in.) Camshaft cap bolts .............................................................................................................................. ...................................................... 19 Nm (14 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2409 Camshaft: Description and Operation VARIABLE CAM TIMING SYSTEM Overview There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded. The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A intake phase shifting system will move the intake cam in the advance direction. The other two possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module (PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems have the added benefit of improve torque. In addition a VCT system will eliminate the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Increased vehicle reliability is achieved with the elimination of the EGR system. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control module) with crankshaft positioning information in 10 degree increments (Figure 132). 1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant temperature), CMP, TP (throttle position), MAF (Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. 5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear piston motion to a rotational motion that advances or retards the camshaft. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2410 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 133) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty near 50%. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The VCT unit assembly (Figure 134) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, a pressure differential occurs forcing the piston to move. This movement is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2411 Camshaft: Service and Repair Camshafts Special Tool(s) Removal 1. Remove the camshaft timing sprockets. 2. NOTE: Measure each valve's clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure each valves clearance and record its location. 3. CAUTION: Cylinder head camshaft journal caps are numbered on the outside flats to make sure that they are assembled in their original positions. Failure to do so may result in engine damage. Remove the camshafts. ^ Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown. ^ Remove the bolts. ^ Remove the caps. 4. Inspect the camshaft runout, lobe lift and journal diameter for wear. ^ Discard the oil seals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2412 5. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. Remove the valve tappets from the cylinder head. 6. NOTE: A midrange clearance is the most desirable: ^ intake: 0.006 in (0.15 mm) ^ exhaust 0.012 in (0.3 mm) NOTE: Select tappets using this formula: tappet thickness = measured clearance plus the base tappet thickness minus most desirable thickness. Select tappets and mark installation location. Installation 1. NOTE: Lubricate the valve tappets with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Install the valve tappets. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2413 2. NOTE: Lubricate the camshaft bearing surfaces with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C 153-H. Install the camshafts. ^ Position the camshafts and camshaft journal caps. ^ Install the bolts and tighten the bolts in several two-turn passes using the sequence shown. 3. NOTE: The front camshaft journal cap must be installed and the bolts tightened to specification within four minutes of sealer application or oil leaks may occur. Coat the sealing surface of the front camshaft journal cap with Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5. 4. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2414 5. Install the camshaft alignment timing tool. 6. NOTE: The exhaust camshaft oil seal is shown, the intake seal is similar. Using the special tool, install new camshaft front oil seals. 7. Install the camshaft timing sprockets. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Camshaft Theoretical valve lift @ 0 lash Intake ................................................................................................................................................... ..................................... 9.254 mm (0.3643 in.) Exhaust ..................................................................... .................................................................................................................. 8.6 mm (0.33858 in.) Lobe lift Intake ................................................................................................................................................... ......................................... 8.9 mm (0.3504 in.) Exhaust ..................................................................... .................................................................................................................... 8.7 mm (0.3425 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2418 Lifter / Lash Adjuster: Service and Repair Valve Tappets Removal 1. Remove the camshafts. 2. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. Remove the valve tappets from the cylinder head. 3. Inspect the valve tappets. 4. NOTE: Make sure the valve tappets are installed in their original locations. To install, reverse the removal procedure. ^ Lubricate the valve tappet with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded. The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A intake phase shifting system will move the intake cam in the advance direction. The other two possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module (PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems have the added benefit of improve torque. In addition a VCT system will eliminate the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Increased vehicle reliability is achieved with the elimination of the EGR system. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control module) with crankshaft positioning information in 10 degree increments (Figure 130). 1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant temperature), CMP, TP (throttle position), MAF (Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. 5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear piston motion to a rotational motion that advances or retards the camshaft. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2422 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty near 50%. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The VCT unit assembly (Figure 132) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, a pressure differential occurs forcing the piston to move. This movement is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting rod bearing bore diameter ................................................................................................................ 46.89-46.91 mm (1.8460591.846847 in.) Connecting rod bearing-to-crankshaft clearance .............................................................................................. 0.016-0.070 mm (0.0006299-0.0027559 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2427 Connecting Rod Bearing: Service and Repair Piston-to-connecting rod clearance .................................................................................................................. 0.016-0.049 mm (0.0006299-0.0019291 in.) Connecting rod pin bore diameter .................................................................................................................... 20.589-20.609 mm (0.810589-0.811376 in.) Connecting rod bearing bore diameter ................................................................................................................ 46.89-46.91 mm (1.8460591.846847 in.) Connecting rod bearing-to-crankshaft clearance .............................................................................................. 0.016-0.070 mm (0.0006299-0.0027559 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Piston-to-connecting rod clearance .................................................................................................................. 0.016-0.049 mm (0.0006299-0.0019291 in.) Connecting rod pin bore diameter .................................................................................................................... 20.589-20.609 mm (0.810589-0.811376 in.) Connecting rod bearing bore diameter ................................................................................................................ 46.89-46.91 mm (1.8460591.846847 in.) Connecting rod bearing-to-crankshaft clearance .............................................................................................. 0.016-0.070 mm (0.0006299-0.0027559 in.) Connecting rod caps. Stage 1 ................................................................................................................................................ ................................................. 35 Nm (26 ft. lbs.) Stage 2 ................................................................. ............................................................................................................................. additional 90 degrees Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main bearing bore inside diameter (bearing caps installed) Standard ....................................................................................................................................................... 58.011-58.0380 mm (2.28389-2.284956 in.) Bearing caps graded by size ....................................................................................................................... 58.008-58.031 mm (2.2837749-2.284680 in.) Crankshaft Main bearing journal diameter ......................................................................................................................... 57.980-58.000 mm (2.2826726-2.28346 in.) Main bearing caps Stage 1 ................................................................................................................................................ ................................................. 25 Nm (18 ft. lbs.) Stage 2 ................................................................. ............................................................................................................................. additional 60 degrees Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main bearing journal diameter ......................................................................................................................... 57.980-58.000 mm (2.2826726-2.28346 in.) Connecting rod journal diameter ......................................................................................................................... 46.89-46.91 mm (1.846059- 1.850036 in.) Crankshaft maximum end play ............................................................................................................................... 0.09-0.26 mm (0.0035433-0.010236 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Block heater screw .............................................................................................................................. ....................................................... 3 Nm (27 in. lbs.) Block heater .................................................... ........................................................................................................................................... 2 Nm (18 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2440 Engine Block Heater: Service and Repair Block Heater Removal and Installation 1. Drain the cooling system. 2. Raise the vehicle. 3. Disconnect the block heater power cable from the block heater. 4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Remove the block heater. 5. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or damage to the cable can occur. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft pulley bolt .......................................................................................................................... ................................................... 115 Nm (85 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2444 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Removal and Installation 1. Raise and support the vehicle. 2. Remove the RF wheel and tire assembly. 3. Remove the bolts and the RH lower splash shield. 4. Loosen the bolt retaining the crankshaft pulley. 5. Remove the accessory drive belt. 6. Remove the bolt and the crankshaft pulley. 7. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston and Connecting Rod Piston diameter Standard ......................................................................................................................................................... 84.758-84.772 mm (3.3369-3.3375 in.) Oversize ......................................................................................................................................................... 85.008-85.022 mm (3.3468-3.3473 in.) Piston-to-cylinder bore clearance ............................................................................................................................. 0.035-0.065 mm (0.0014-0.0025 in.) Piston Ring End Gap Piston ring groove width Upper compression ring ....................................................................................................................................................... 1.484 mm (0.058425 in.) Lower compression ring ..................................................................................................................................................... 1.734 mm (0.0682675 in.) Oil control ring ........................................................................................... ........................................................................ 2.905 mm (1.1143698 in.) Piston ring width Upper and lower compression ring ................................................................................................................ 0.30-0.50 mm (0.011811-0.019685 in.) Oil control ring .............................................................................................................................................. 0.40-1.40 mm (0.015748-0.055118 in.) Piston Pin Bore Diameter Piston pin diameter White ................................................................................................................................................. 20.662-20.625 mm (0.8134629-0.8120062 in.) Red ..................................................................................................................................................... 20.625-20.628 mm (0.8120062-0.8121243 in.) Blue .................................................................................................................................................... 20.628-20.631 mm (0.8121243-0.8122424 in.) Piston pin length ................................................................................................................................................. 63.00-63.80 mm (2.48031 -2.51181 in.) Piston pin-to-piston fit ................................................................................................................................. 0.010-0.015 mm (0.0003937-0.0005905 in.) Piston-to-connecting rod clearance .............................................................................................................. 0.016-0.049 mm (0.0006299-0.0019291 in.) Connecting rod pin bore diameter ................................................................................................................ 20.589-20.609 mm (0.810589-0.811376 in.) Connecting rod bearing bore diameter ............................................................................................................ 46.89-46.91 mm (1.8460591.846847 in.) Connecting rod bearing-to-crankshaft clearance .......................................................................................... 0.016-0.070 mm (0.0006299-0.0027559 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston pin diameter-white ............................................................................................................................ 20.662-20.625 mm (0.8134629-0.8120062 in.) Piston pin diameter-red ................................................................................................................................ 20.625-20.628 mm (0.8120062-0.8121243 in.) Piston pin diameter-blue .............................................................................................................................. 20.628-20.631 mm (0.8121243-0.8122424 in.) Piston pin length ...................................................................................................................................................... 63.00-63.80 mm (2.48031-2.51181 in.) Piston pin-to-piston fit ..................................................................................................................................... 0.010-0.015 mm (0.0003937-0.0005905 in.) Connecting rod pin bore diameter .................................................................................................................... 20.589-20.609 mm (0.810589-0.811376 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston ring groove width-upper compression ring .......................................................................................................................... 1.484 mm (0.058425 in.) Piston ring groove width-lower compression ring ........................................................................................................................ 1.734 mm (0.0682675 in.) Piston ring groove width-oil control ring ..................................................................................................................................... 2.905 mm (1.1143698 in.) Piston ring width-upper and lower compression ring ............................................................................................... 0.30-0.50 mm (0.011811-0.019685 in.) Piston ring width-oil control ring ............................................................................................................................. 0.40-1.40 mm (0.015748-0.055118 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve clearance - intake ........................................................................................................................................... 0.11-0.18 mm (0.004331-0.007087 in.) Valve clearance - exhaust .................................................................................................................................... 0.27-0.34 mm (0.0106299-0.0133858 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 2458 Valve Clearance: Service and Repair Valve-Valve Clearance, Adjust Special Tool(s) Removal 1. Remove the timing belt. 2. Remove the camshaft alignment tool. 3. NOTE: Measure each valve's clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure each valves clearance and record its location. 4. Remove the camshafts. 5. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 2459 Remove the valve tappets from the cylinder head. 6. NOTE: A midrange clearance is the most desirable: ^ intake: 0.15 mm (0.006 in.) ^ exhaust: 0.3 mm (0.012 in.) NOTE: Select tappets using this formula: tappet thickness = measured clearance plus the base tappet thickness minus most desirable thickness. Select tappets and mark installation location. Installation 1. NOTE: Lubricate the valve tappets with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Install the valve tappets. 2. Install the camshafts. 3. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet. 4. Install the camshaft alignment tool. 5. Install the timing belt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2463 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve cover bolts ................................................................................................................................. ...................................................... 9 Nm (80 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 2467 Valve Cover: Service and Repair Valve Cover Removal and Installation 1. Remove the air cleaner outlet pipe. 2. Remove the ignition wires from the spark plugs. 3. Disconnect the throttle cables. ^ Disconnect the speed control actuator cable (if equipped). ^ Disconnect the accelerator cable. 4. Disconnect the catalyst monitor and heated oxygen sensor electrical connectors. Detach the electrical connectors from the bracket. 5. Remove the wiring harness anchors from the valve cover studs and position the wiring harness aside. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 2468 6. Remove the valve cover. 1 Remove the stud bolts 2 Remove the bolts. 7. CAUTION: The valve cover sealing surfaces are soft materials. Do not use abrasive grinding discs to remove gasket material; only use manual scrapers. Do not scratch or gouge sealing surfaces or oil leaks may occur. Clean and inspect the sealing surfaces of the valve cover and the cylinder head. Both surfaces must be clean and flat. 8. To install, reverse the removal procedure. ^ Install a new valve cover gasket if damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve spring free length ....................................................................................................................... .................................................. 43.2 mm (1.701 in.) Valve spring compression pressure-intake ............................................................................................................. 365 N (82.1 lbs.) @ 25.1 mm (0.988 in.) Valve spring compression pressure-exhaust ...................................................................................................... 422 N (94.94 lbs.) @ 26.1 mm (1.0275 in.) Valve spring installed height ............................................................................................. ..................................................................... 34.2 mm (1.346 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2472 Valve Spring: Service and Repair Valve-Valve Spring, Valve Spring Retainer and Valve Stem Seal Special Tool(s) Removal 1. Remove the spark plugs. 2. Remove the valve tappets. 3. NOTE: If the air pressure fails to hold the valves closed while carrying out the following steps, valve or valve seat damage is indicated and the cylinder head must be removed. NOTE: Make sure the applicable piston is at the top of its stroke. Install the air line with an adapter in the spark plug hole and turn on the air supply. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2473 4. Install the special tools, compress the valve spring, and remove the valve spring retainer and valve spring. 5. Inspect the valve spring, valve spring retainer and valve spring retainer key. Install new parts as necessary. 6. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve(s) to fall into the cylinder. A rubber band, tape or string wrapped around the end of the valve stem will prevent this from happening. Use the special tools to remove the valve stem seal. Installation 1. CAUTION: If the valve has been damaged, removal will be necessary for repair. Remove the air pressure from the spark plug adapter and inspect the valve for damage. Rotate the valve and check the valve for eccentric movement during rotation. 2. If the condition of the valve is satisfactory, apply Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H to the valve stem and hold the valve closed. Apply the air pressure within the cylinder. 3. Lubricate valve and guides with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H and using the special tool install the valve stem seals onto the cylinder head valve guides. 4. Place the valve spring in position over the valve and install the valve spring retainer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2474 5. Using the special tools compress the valve spring and install the valve spring retainer keys. ^ Remove the special tools. 6. Remove the air pressure. 7. Remove the air line adapter. 8. Install the valve tappets. 9. Install the spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Without A/C Drive Belt: Locations Without A/C 2.0L Zetec without A/C 2.0L Zetec Without A/C Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Without A/C > Page 2480 Drive Belt: Locations With A/C 2.0L Zetec with A/C 2.0L Zetec With A/C Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 2481 Drive Belt: Diagrams 2.0L Zetec Without A/C 2.0L Zetec With A/C Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Accessory Drive Inspection and Verification 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the mechanical concerns apply. 3. NOTE: Minor cracks in the V-grooved portion of the drive belt are considered normal and acceptable. If the drive belt has chunks missing from the ribs, a new drive belt should be installed. Install a new drive belt if any of the following conditions exist: rib chunk-out, severe glazing, frayed cords or other concerns. Inspect for drive belt cracking/chunking/wear. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Serpentine Drive Belt With Cracks Across Ribs V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) V-Ribbed Serpentine Drive Belt With Chunks of Rib Missing 4. If the concerns remain after inspection, determine the symptoms. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2484 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Part 1 Of 2 Part 2 Of 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2485 Drive Belt: Component Tests and General Diagnostics Belt Tensioner Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. Remove the belt in the area of the tensioner. 2. Rotate the 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 that there is tension on the belt tensioner spring. 3. If the tensioner meets the above criteria, proceed to test the tensioner dynamically. If the tensioner does not meet the above criteria, install a new tensioner. Belt Tensioner Dynamic The belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the belt tensioner movement. The belt tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can be checked by installing a new drive belt, and repeating the observation. 2. With the engine off, check routing of the drive belt. 3. Inspect the belt tensioner wear indicator to confirm the drive belt is within operating range. Install a new drive belt if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2486 Drive Belt: Service and Repair Accessory Drive Belt-2.0L Zetec Removal and Installation 1. Remove the right front wheel and tire. 2. Remove the bolts and the right front lower splash shield. 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner-2.0L Zetec Removal and Installation 1. Remove the accessory drive belt. 2. Remove the bolts and the accessory drive belt tensioner. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine mount bolts/nut ........................................................................................................................ ..................................................... 55 Nm (41 ft. lbs.) Engine mount ground wire nut (engine) ..................................................................................................................................................... 9 Nm (80 in. lbs.) Engine mount ground wire bolt (body) .................................................................................................................................................... 10 Nm (89 in. lbs.) Engine mount lower bracket bolts ............................................................................................................................................................ 50 Nm (37 ft. lbs.) Engine mount bolts/nut .......................................................................................... ................................................................................... 34 Nm (25 ft. lbs.) Engine/transaxle mounting bolts ..................................................................................................................................................... .......... 45 Nm (33 ft. lbs.) Lower engine mount bracket bolts ............................................................................................................................................................ 50 Nm (37 ft. lbs.) Lower engine mount bracket studs ........................................................................................................................................................... 34 Nm (25 ft. lbs.) LH engine support insulator bolts ............................................................................................................................................................. 70 Nm (52 ft. lbs.) LH engine support insulator nut ............................................................................. .................................................................................. 90 Nm (66 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 2493 Engine Mount: Service and Repair Engine Mount Special Tool(s) Removal and Installation 1. Install the special tool. 2. Disconnect the ground strap. 3. Remove the engine mount upper bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 2494 4. Disconnect the ground wire. 5. Disconnect the power steering line bracket. 6. Disconnect the power steering line bracket and position the line aside. 7. Remove the engine mount. 8. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Accessory drive belt idler pulley .............................................................................................................................................................. 45 Nm (35 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2498 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley-2.0L Zetec Removal and Installation 1. Remove the accessory drive belt. 2. Remove the bolt and the accessory drive belt idler pulley. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure (hot 4,000 rpm) ........................................................................................................................................................... 370-550 kPa (54-80 psi) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Level Indicator Markings Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Oil Level Indicator Markings Article No. 03-8-3 04/28/03 ENGINE - ENGINE OIL LEVEL INDICATOR MARKINGS - REPORTS OF LOW OIL LEVELS FORD: 2002 ESCORT 2002-2003 CROWN VICTORIA, ESCORT ZX2, FOCUS, MUSTANG, TAURUS, THUNDERBIRD, E SERIES, ESCAPE, EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, WINDSTAR LINCOLN: 2002 CONTINENTAL 2002-2003 LS, TOWN CAR, NAVIGATOR 2003 AVIATOR MERCURY: 2002-2003 COUGAR, GRAND MARQUIS, SABLE 2002 VILLAGER 2002-2003 MOUNTAINEER ISSUE Reports from the field indicate incorrect or low engine oil levels are being found at Pre-Delivery Inspection on new vehicles received in dealer inventory. In most cases, the level is being misinterpreted because the fluid fill mark on the stick is not touching the top hash mark at the upper limit (or MAX mark), or is partway down the crosshatch area. ACTION Ford is in the process of standardizing the markings across all vehicle lines. Current markings shown will be upgraded to a refined marking, shown in Figure 1. Both markings will be used in production over the next few years. Oil levels will still be recorded in the crosshatched area of the blade, between the upper and lower limit holes. Vehicles shipped with engine oil levels falling within this area are acceptable and do not require topping off. Oil fill quantities are precisely measured at the plants and account for slight variations that may occur in oil pan volumes, indicator length, and pressed-in locations of the indicator tube into the block. For customer use, the markings continue to serve as a guide to refilling the engine to the correct initial fill volume with filter or, to top off the engine when it is determined the level is below the lower hole. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Level Indicator Markings > Page 2507 SERVICE INFORMATION Ensure the vehicle is sitting on level ground. Set the park brake and ensure the transmission selector lever is in PARK position, or in FIRST gear on manuals. The engine must be OFF. The best time for determining oil level is before the engine is started and the oil has had sufficient drainback time to the sump. If the engine has been running, allow it to sit for a few minutes turned off. An oil drainback period is required before taking an initial reading. If the level falls below the lower hole, fill with one quart of oil. If one quart is insufficient to raise the level above the mark, add oil until it records within the crosshatch area. Use caution during this procedure as some time is needed for oil to drain down through the drainback passages in the cylinder head, to the oil pan. Adding oil a quart at a time repeatedly without sufficient drainback may overfill the sump. If the oil level falls between the upper and lower hole do not add more oil. Adding an extra quart could cause overfilling and may result in aeration (foaming) causing eventual damage to vital bearing surfaces and moving parts inside. Overfilling will require some oil to be drained out until the indicator shows the level between the upper and lower holes of the blade. DO NOT expect the engine to 'consume" the extra oil back down to the upper oil till level hole, or consider it as extra lubrication protection for the engine. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Page 2508 Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil level indicator and tube nut ............................................................................................................ .................................................... 10 Nm (89 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Page 2509 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Removal and Installation 1. Remove the bolt and the oil level indicator and tube. 2. To install, reverse the removal procedure. ^ Install a new O-ring seal if damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ........................................................... 4.25L (4.5 Qt) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2514 Engine Oil: Fluid Type Specifications Engine Oil .............................................................................................................................. Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil cooler bolt ....................................................................................................................................... .................................................... 58 Nm (43 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2518 Oil Cooler: Service and Repair Oil Cooler Removal and Installation 1. Drain the engine coolant. 2. Remove the oil filter. 3. Remove the oil cooler. ^ Disconnect the coolant hoses. ^ Remove the cooler mounting bolt. 4. CAUTION: The oil cooler sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; only use manual scrapers. Do not scratch or gouge sealing surfaces or oil leaks may occur. Carefully clean the sealing surfaces. ^ Install a new oil filter. 5. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil filter ................................................................................................................................................ .................................................... 16 Nm (12 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan drain plug ................................................................................................................................ ..................................................... 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2525 Oil Pan: Service and Repair Oil Pan Removal 1. Remove the catalytic converter. 2. Drain the engine oil. ^ Install the drain plug. 3. Remove the 17 bolts and the oil pan. Installation 1. CAUTION: The oil pan sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; use only manual scrapers. Do not scratch or gouge the aluminum sealing surfaces. Clean and inspect the mounting faces of both the oil pan and the cylinder block with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A. Both surfaces must be flat, clean and dry. 2. NOTE: The oil pan must be installed and the bolts tightened to specification within seven minutes of sealer application or oil leaks may occur. NOTE: Apply a 3 mm (0.1 in.) continuous bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the oil pan. Install the oil pan. Tighten the bolts using the sequence shown in two stages: ^ Stage 1: Tighten to 6 Nm (53 in. lbs.). ^ Stage 2: Tighten 12 Nm (9 in. lbs.). 3. Install the catalytic converter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2526 4. Fill the crankcase with Super Premium SAL 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sender ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2530 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2531 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2532 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. NOTE: The halfshaft is removed for clarity. Disconnect the oil pressure sender electrical connector. 3. Remove the oil pressure sender. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil pump screen cover and tube bolts ...................................................................................................................................................... 10 Nm (89 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Page 2536 Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Removal and Installation 1. Remove the oil pan. 2. Remove the oil pump screen cover and tube. ^ Remove and discard the gasket. 3. CAUTION: The oil pump screen cover and tube sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; only use manual scrapers. Do not scratch or gouge sealing surfaces. Carefully clean both sealing surfaces. 4. To install, reverse the removal procedure. ^ Install a new gasket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure (hot 4,000 rpm) ........................................................................................................................................................... 370-550 kPa (54-80 psi) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold bolts Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2544 Intake Manifold: Service and Repair Intake Manifold Removal 1. WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components to prevent possible injury. Failure to follow these instructions can result in personal injury. Remove the fuel injection supply manifold. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Disconnect the idle air control (IAC) electrical connector and unclip the harness from the bracket. 4. Disconnect the main engine control sensor wiring and remove the connector from the mounting bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2545 5. Disconnect the powertrain control module (PCM) wire harness from the bracket. 6. Disconnect the heated oxygen sensor (H02S) wiring harness from the bracket. 7. Remove the HO2S wiring harness retainer. 8. Disconnect the cylinder head temperature (CHT) sensor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2546 9. Detach the CHT sensor wiring harness from the clip, and remove the clip. 10. Disconnect the brake booster vacuum supply hose. 11. Disconnect the four vacuum hoses. 12. Disconnect the positive crankcase ventilation (PCV) vacuum hose. 13. Remove the generator. 14. Remove the exhaust gas recirculation (EGR) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2547 15. NOTE: Illustration shown with throttle body removed for clarity. Remove the intake manifold. ^ Remove the two nuts and five bolts in the sequence shown. 16. Remove and inspect the intake manifold gaskets. ^ Discard if damaged. Installation 1. NOTE: Illustration shown with the throttle body removed for clarity. NOTE: Install new intake manifold gaskets if damaged. Install the intake manifold and tighten using the sequence shown. 2. NOTE: The EGR valve sealing surfaces are soft metals. Carefully clean all sealing surfaces and install a new EGR valve gasket. Install the EGR valve bolts. 3. Install the generator. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2548 4. Connect the PCV vacuum hose. 5. Connect the four vacuum hoses. 6. Connect the brake booster vacuum supply hose to the intake manifold. 7. Install the (CHT) sensor wire clip, and attach the CHT wiring harness. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2549 8. Connect the (CHT) sensor. 9. Install the retainer for the H02S wiring harness mount. 10. Connect the H02S sensor wiring harness to the bracket. 11. Connect the PCM wiring harness to the bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2550 12. Connect the main engine control sensor wiring. 13. Connect the IAC electrical connector and attach the wiring harness to the bracket. 14. Connect the TP sensor electrical connector. 15. Install the fuel injection supply manifold. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Service and Repair Camshaft Oil Seal: Service and Repair Camshaft Oil Seal Special Tool(s) Removal 1. Remove the camshaft timing sprockets. 2. NOTE: The exhaust camshaft oil seal is shown, the intake camshaft oil seal is similar. Using the special tool, remove the camshaft oil seals. Installation 1. NOTE: The exhaust camshaft oil seal is shown, the intake seal is similar. Using the special tool, install new camshaft front oil seals. 2. Install the camshaft timing sprockets. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Special Tool(s) Removal 1. Remove the flywheel. 2. CAUTION: Use care to avoid damaging the crankshaft sealing surface. Using the special tool, remove the crankshaft rear oil seal. 3. Inspect the crankshaft rear oil seal area. Installation 1. NOTE: Coat the rear oil seal area and the crankshaft rear oil seal lip with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2558 NOTE: Make sure the crankshaft rear oil seal is on correctly and that the edges are not rolled over. Using the special tools, install the crankshaft rear oil seal. 2. Install the flywheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2563 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2564 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2565 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Special Tool(s) Removal 1. Remove the timing belt. 2. Remove the crankshaft sprocket and timing belt guide. 3. CAUTION: Use care to avoid damaging the crankshaft surface. Using the special tool. remove the crankshaft front seal from the oil pump. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2569 1. Using the special tool, install a new crankshaft front seal. 2. Install the timing belt guide and crankshaft sprocket. 3. Install the timing belt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve-Valve Spring, Valve Spring Retainer and Valve Stem Seal Special Tool(s) Removal 1. Remove the spark plugs. 2. Remove the valve tappets. 3. NOTE: If the air pressure fails to hold the valves closed while carrying out the following steps, valve or valve seat damage is indicated and the cylinder head must be removed. NOTE: Make sure the applicable piston is at the top of its stroke. Install the air line with an adapter in the spark plug hole and turn on the air supply. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2573 4. Install the special tools, compress the valve spring, and remove the valve spring retainer and valve spring. 5. Inspect the valve spring, valve spring retainer and valve spring retainer key. Install new parts as necessary. 6. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve(s) to fall into the cylinder. A rubber band, tape or string wrapped around the end of the valve stem will prevent this from happening. Use the special tools to remove the valve stem seal. Installation 1. CAUTION: If the valve has been damaged, removal will be necessary for repair. Remove the air pressure from the spark plug adapter and inspect the valve for damage. Rotate the valve and check the valve for eccentric movement during rotation. 2. If the condition of the valve is satisfactory, apply Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H to the valve stem and hold the valve closed. Apply the air pressure within the cylinder. 3. Lubricate valve and guides with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H and using the special tool install the valve stem seals onto the cylinder head valve guides. 4. Place the valve spring in position over the valve and install the valve spring retainer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2574 5. Using the special tools compress the valve spring and install the valve spring retainer keys. ^ Remove the special tools. 6. Remove the air pressure. 7. Remove the air line adapter. 8. Install the valve tappets. 9. Install the spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sender ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2579 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2580 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2581 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. NOTE: The halfshaft is removed for clarity. Disconnect the oil pressure sender electrical connector. 3. Remove the oil pressure sender. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolts ...................................................................................................................... ...................................................... 68 Nm (50 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications Timing Belt: Specifications Upper timing belt cover bolts ............................................................................................................... ...................................................... 8 Nm (71 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2589 Timing Belt: Service and Repair Timing Belt Special Tool(s) Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet pipe. 3. Remove the spark plugs. 4. Disconnect the throttle cables. ^ If equipped, disconnect the speed control actuator cable. ^ Disconnect the accelerator cable. 5. Disconnect the catalyst monitor and heated oxygen sensor electrical connectors. Detach the electrical connectors from the bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2590 6. Remove the wiring harness anchors from the valve cover studs and position the wiring harness aside. 7. Remove the valve cover. 1 Remove the stud bolts. 2 Remove the bolts. 8. CAUTION: The valve cover sealing surfaces are soft materials. Do not use abrasive grinding discs to remove gasket material. Use only a plastic scraping tool. Do not scratch or gouge sealing surfaces or oil leaks can occur. Clean and inspect the sealing surfaces of the valve cover and cylinder head. Both surfaces must be clean and flat. 9. Remove the catalytic converter. 10. Remove the bolt and nut and position the coolant tube aside. 11. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching of the center cap, place face up when removed. Remove the wheel and tire assembly. 1 Remove the center cap. 2 Remove the wheel nuts. 3 Remove the wheel and tire assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2591 12. Remove the RH lower splash shield. 13. Rotate the crankshaft to just before top dead center (TDC) (No. 1 cylinder). 14. Remove the stud. 15. Install the special tool. 16. NOTE: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2592 Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder). 17. Loosen the water pump pulley bolts. 18. Loosen the crankshaft pulley bolt. 19. Rotate the tensioner and remove the accessory drive belt. 20. Remove the bolt and the crankshaft pulley. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2593 21. Remove the bolts and the lower timing belt cover. 22. Lower the vehicle. 23. Install the special tool. 24. Detach the ground strap. 25. Remove the nuts, the bolt and the engine mount upper bracket. 26. Remove the studs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2594 27. Detach the knock sensor electrical connector from the upper timing cover. 28. Remove the bolts and the upper timing cover. 29. Remove the water pump pulley. 30. Remove the accessory drive belt idler pulley. 31. NOTE: Installation of the alignment tool into the exhaust camshaft can require the camshafts to be rotated clockwise slightly. Install the special tool and align the camshafts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2595 32. Raise the vehicle. 33. Remove the bolts and the engine mount lower bracket. 34. Loosen the timing belt tensioner pulley and allow to slide down to the bottom of its travel. 35. CAUTION: If the camshaft timing belt is to be reused, mark the direction of the camshaft timing belt to rotation of camshaft prior to removal or premature wear or failure can occur. Slide the timing belt off of the camshaft and crankshaft sprockets. 36. Inspect the timing belt for wear. Install a new belt if necessary. Installation 1. NOTE: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg. ^ Remove the crankshaft pulley. 2. Lower the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2596 3. Confirm that the timing belt tensioner is installed correctly with the tab positioned in the slot in the inner timing cover. 4. Install the timing belt onto the timing belt sprockets. 5. Adjust the timing belt tensioner. 1 Using a 6 mm Allen wrench, rotate the adjuster counterclockwise and align the marks as shown. 2 Tighten the tensioner pulley bolt. 6. CAUTION: The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft can result. NOTE: Use an open-end wrench to keep each camshaft from rotating. If the timing sprockets were removed. tighten the camshaft timing sprocket bolts to specifications. 7. Raise the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2597 8. Install the front engine mount lower bracket. 9. Install the accessory drive belt idler pulley. 10. Install the water pump pulley. ^ Hand-tighten the bolts. 11. Lower the vehicle. 12. Position the upper timing belt cover and install the bolts. 13. Install the studs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2598 14. Connect the knock sensor electrical connector to the upper timing belt cover. 15. Install the engine mount upper bracket, the nuts and the bolt. 16. Attach the ground strap and install the nut. 17. Remove the special tool. 18. Raise the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2599 19. Position the lower timing belt cover and install the bolts. 20. Position the crankshaft pulley and install the bolt. ^ Hand-tighten the bolt. 21. Rotate the tensioner and install the accessory drive belt. 22. Tighten the crankshaft pulley bolt. 23. Tighten the water pump pulley bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2600 24. Position the RH lower splash shield and install the bolts 25. WARNING: Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions can result in personal injury. Clean the wheel hub mounting surface and the wheel pilot 26. Install the wheel and tire assembly 1 Position the wheel and tire assembly 2 Install the wheel nuts hand-tight 27. Remove the special tool. 28. Install the stud 29. Install the coolant tube. 30. Install the catalytic converter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2601 31. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in the sequence shown. 32. Install the center cap. 33. Remove the special tool. 34. Inspect the valve cover gasket. Install a new gasket, if necessary. 35. Position the valve cover. 1 Install the stud bolts. 2 Install the bolts. 36. Connect the wiring harness anchors to the valve cover studs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 2602 37. Attach the catalyst monitor and heated oxygen sensor electrical connectors to the bracket. Connect the electrical connectors. 38. Connect the throttle cables. ^ Connect the accelerator cable. ^ If equipped, connect the speed control actuator cable. 39. Install the spark plugs. 40. Install the air cleaner outlet pipe. 41. Connect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Idler Pulley > Component Information > Specifications Timing Belt Idler Pulley: Specifications Timing belt idler pulley bolt .................................................................................................................. ................................................... 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Timing belt tensioner bolt .................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair Timing Belt Cover-Upper and Lower Special Tool(s) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the crankshaft pulley. 3. Remove the bolts and the lower timing belt cover. 4. Lower the vehicle. 5. Install the special tool. 6. Remove the ground strap. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 2612 7. Remove the engine mount upper bracket. 8. Remove the studs. 9. Remove the knock sensor connector. 10. Remove the bolts and the upper timing belt cover. 11. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded. The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A intake phase shifting system will move the intake cam in the advance direction. The other two possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module (PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems have the added benefit of improve torque. In addition a VCT system will eliminate the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Increased vehicle reliability is achieved with the elimination of the EGR system. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control module) with crankshaft positioning information in 10 degree increments (Figure 130). 1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant temperature), CMP, TP (throttle position), MAF (Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. 5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear piston motion to a rotational motion that advances or retards the camshaft. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2617 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty near 50%. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The VCT unit assembly (Figure 132) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, a pressure differential occurs forcing the piston to move. This movement is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the air cleaner. 2. Remove the battery tray. 3. Remove the bolt and the intake pipe. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the front sponge seal of the intake pipe is seated on the shroud panel correctly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2631 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications 4-Cyl Firing Order: 1 3 4 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2635 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. ^ Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2643 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and with a twisting-pulling motion, disconnect the ignition wires from the spark plugs. CAUTION: Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. 2. Disconnect the ignition wires from the ignition coil and remove the wires. INSTALLATION 1. Connect the ignition wires to the correct ignition coil terminals. CAUTION: Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. NOTE: ^ Whenever an ignition wire is reinstalled or a new one is installed, apply Silicone Brake Caliper Grease and Dielectric compound to the interior surface of the ignition wire boot. ^ Before installing the ignition wires, inspect the ignition wires for any visible damage; install new ignition wires if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2644 2. Connect the ignition wires to the correct spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap Spark Plug Gap 0.048-0.052 inch (1.22-1.32 mm) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2648 Spark Plug: Service Precautions CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2649 Spark Plug: Application and ID Spark plug cylinders 1 and 3................................................................................................................ ....................................................................AZFS-32F Spark plug cylinders 2 and 4........................... .......................................................................................................................................................AZF S-32FE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2650 Spark Plug: Service and Repair REMOVAL CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. 1. Grasp the spark plug boot firmly and with a twisting-pulling motion remove the spark plug wires from the spark plug. 2. Remove the spark plugs. NOTE: ^ If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs can be used in any cylinder. ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs. INSTALLATION 1. Adjust the plug gap as necessary. NOTE: Clean the spark plugs with a wire brush or a professional spark plug cleaner (follow the manufacture's instructions). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2651 2. Install the spark plugs. NOTE: Apply Anti-Seize Lubricant to the lower three threads of the spark plugs. Do not allow lubricant to contaminate the spark plug electrodes or insulator tips. 3. Connect the spark plug wires to the spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2655 Compression Check: Testing and Inspection Compression Test Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the 0FF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2656 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve clearance - intake ........................................................................................................................................... 0.11-0.18 mm (0.004331-0.007087 in.) Valve clearance - exhaust .................................................................................................................................... 0.27-0.34 mm (0.0106299-0.0133858 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2660 Valve Clearance: Service and Repair Valve-Valve Clearance, Adjust Special Tool(s) Removal 1. Remove the timing belt. 2. Remove the camshaft alignment tool. 3. NOTE: Measure each valve's clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure each valves clearance and record its location. 4. Remove the camshafts. 5. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2661 Remove the valve tappets from the cylinder head. 6. NOTE: A midrange clearance is the most desirable: ^ intake: 0.15 mm (0.006 in.) ^ exhaust: 0.3 mm (0.012 in.) NOTE: Select tappets using this formula: tappet thickness = measured clearance plus the base tappet thickness minus most desirable thickness. Select tappets and mark installation location. Installation 1. NOTE: Lubricate the valve tappets with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Install the valve tappets. 2. Install the camshafts. 3. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet. 4. Install the camshaft alignment tool. 5. Install the timing belt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water pump pulley bolts ...................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info Coolant: Technical Service Bulletins Cooling System - Premium Gold Coolant Service Info Article No. 02-23-7 11/25/02 COOLING SYSTEM - MOTORCRAFT PREMIUM GOLD ENGINE COOLANT - SERVICE TIPS FORD: 2002-2003 ESCORT ZX2, FOCUS, MUSTANG, TAURUS, THUNDERBIRD 2003 CROWN VICTORIA 2002 EXCURSION 2002-2003 E SERIES, ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2003 EXPEDITION, WINDSTAR 2002-2003 F-650, F-750 LINCOLN: 2002 CONTINENTAL 2002-2003 LS 2003 TOWN CAR 2002-2003 BLACKWOOD 2003 AVIATOR, NAVIGATOR MERCURY: 2002-2003 SABLE 2003 GRAND MARQUIS 2002-2003 MOUNTAINEER Article 02-17-7 is being republished in its entirety to update the text and part numbers. ISSUE A new, extended-life engine coolant, yellow-colored Motorcraft Premium Gold Engine Coolant, meeting Ford Specification WSS-M97B51-A1, service part numbers VC-7-A and VC-7-C (for use in the U.S., except California and Oregon) and VC-7-B (for use only in California and Oregon as it contains a bittering agent), has been equipped in all of the vehicles noted above. The initial-fill life for this coolant is 100,000 miles/5 years. Due to variations in water quality, the replacement interval is 50,000 miles/3 years. ACTION Any time the addition of coolant or a coolant change-out is required, USE ONLY THE TYPE OF ENGINE COOLANT WITH WHICH THE VEHICLE WAS ORIGINALLY EQUIPPED. DO NOT MIX COOLANT TYPES. To determine the type of coolant required, check the color of coolant in the coolant reservoir of the vehicle or refer to the applicable vehicle's Owner's Guide or Workshop Manual for service parts and specification information. SERVICE INFORMATION Except for heavy-duty vehicles equipped with the Caterpillar 3126E engine, the use of a supplemental coolant additive (SCA) such as Motorcraft Heavy-Duty Cooling System Additive, service part number FW-16, is not required in conjunction with this coolant. Testing is currently underway to determine the backward compatibility of the Motorcraft Premium Gold Engine Coolant in vehicles equipped with the green-colored Motorcraft Premium Engine Coolant, service part numbers VC-4-A, VC-4-B, and VC-5. Until the final test results are available, vehicles should ONLY be serviced with type of coolant with which they were originally equipped. Please note that Motorcraft Premium Gold Engine Coolant is not compatible with any orange-colored, extended-life engine coolants such as Motorcraft Specialty Orange Engine Coolant, service part numbers VC-2 and VC-3. DO NOT MIX COOLANT TYPES. USE ONLY THE TYPE OF COOLANT WITH WHICH THE VEHICLE WAS EQUIPPED. Failure to follow these guidelines may result in degradation of corrosion protection and potential engine damage. Coolant Discoloration: The current Motorcraft Cooling System Stop Leak Pellets, service part number VC-6, used in both Production and Service, cause the yellow-colored Motorcraft Premium Gold Engine Coolant to change color ranging from a light golden brown to dark brown, depending upon the amount of pellet Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2671 material in the coolant reservoir. This discoloration does not adversely affect the coolant or the vehicle's cooling system components. No repairs are required for this condition. To avoid confusion with regard to coolant contamination, a new formulation of stop leak pellets will be implemented in Production and Service in the near future. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-17-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Coolant: Pressure, Vacuum and Temperature Specifications Cooling System Pressure Test Specification Radiator ............................................................................................................................................... .................................................... 138 kPa (20 psi) Radiator Cap Pressure Test Specification Radiator cap ..................................................................................................................................................... 110 + 14 kPa - 21 kPa (16 + 2 psi - 3 psi) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2674 Coolant: Capacity Specifications Fluid Capacity (Manual trans) .............................................................................................................. .............................................................. 7.0L (7.4 qt) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2675 Coolant: Fluid Type Specifications Coolant Types Caution: Do not mix coolant types. Motorcraft Premium Engine Coolant ......................................................... VC-4-A (in Oregon VC-5, in Canada CXC-10) ESE-M97B44-A (green color) Motorcraft Premium Gold Engine Coolant ...................................................................... VC-7-A (in Oregon VC-7-B) WSS-M97H51-A11 (yellow color) Motorcraft Premium Cooling System Flush ......................................................................................................................................... VC-1 ESR-M14F7-A Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Level Sensor: Customer Interest Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 2684 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Level Sensor: All Technical Service Bulletins Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 2690 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Level Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Level Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2696 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Level Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2697 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Level Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2703 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant Level Sensor: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2704 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 2705 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 2706 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Coolant tube bolt/nut ........................................................................................................................... ..................................................... 20 Nm (15 ft. lbs.) Coolant tube bracket bolt (oil cooler) ...................................................................................................................................................... 10 Nm (89 in. lbs.) Coolant tube stud ....................................................................................................... ............................................................................... 24 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Reservoir: Customer Interest Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 2718 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Reservoir: All Technical Service Bulletins Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 2724 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Page 2725 Coolant Reservoir: Service and Repair Degas Bottle Removal and Installation 1. Drain the engine cooling system. 2. Remove the degas bottle. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Connector Views Radiator Cooling Fan Motor: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 2735 Radiator Cooling Fan Motor Relay: Locations Medium Speed Fan Control Relay Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 2736 View 151-12 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 2737 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 2740 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 2741 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 2742 Radiator Cooling Fan Motor Relay: Diagrams Medium Speed Fan Control Relay Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2743 Radiator Cooling Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2744 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2755 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2756 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2765 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2766 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2772 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2773 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Technician Safety Information Heater Core: Technician Safety Information WARNING: ^ CARBON MONOXIDE GAS IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Technician Safety Information > Page 2776 Heater Core: Vehicle Damage Warnings CAUTION: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2777 Heater Core: Description and Operation Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the heater core housing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2778 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE GAS IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the Plugged Heater Core Component Test before the Heater Core Pressure Test. Carry out a system inspection by checking the heater system thoroughly. CAUTION: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. 2. Check the integrity of the heater water hose clamps. Heater Core - Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: ^ the heater core may have an air pocket. ^ the heater core may be plugged, or ^ the thermostat is not working correctly. Heater Core - Pressure Test Use the radiator/heater core pressure tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2779 tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service Precautions > Page 2780 Heater Core: Service and Repair REMOVAL 1. Drain the engine coolant. NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. 2. Disconnect the heater hoses from the heater core. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Remove the heater blending door levers. 1 Remove the screw for heater blending door. 2 Remove the levers for the blending door. 5. Remove the heater core. 1 Remove the three screws. 2 Remove the cover for the heater core and pull the heater core out of the housing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Before installing the temperature control cable, make sure the blend door, cable and temperature switch are correctly positioned. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2789 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2790 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2796 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2797 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 2798 Heater Hose: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Disconnect the heater hose from the hose connection. 4. Remove the RH front wheel. 5. Disconnect the heater hose from the hose connection. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the hoses with Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Removal and Installation 1. Drain the engine cooling system. 2. Raise and support the vehicle. 3. Remove the lower splash shields. 4. Disconnect the lower radiator hose and the degas return hose. 5. Lower the vehicle. 6. Disconnect the remaining coolant hose connections. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2802 7. Position the hood latch assemble out of the way. 8. Remove the two bolts and the center support. 9. Remove the two top bolts retaining the cooling fan to the radiator. 10. Remove the upper radiator support brackets, and remove the radiator from the vehicle. 11. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 2808 Radiator Cooling Fan Motor Relay: Locations Medium Speed Fan Control Relay Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 2809 View 151-12 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Control Relay 1 > Page 2810 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 2813 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 2814 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Fan Control Relay 1 > Page 2815 Radiator Cooling Fan Motor Relay: Diagrams Medium Speed Fan Control Relay Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2816 Radiator Cooling Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2817 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Level Sensor: Customer Interest Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Customer Interest for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 2827 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON Coolant Level Sensor: All Technical Service Bulletins Cooling System - Low Coolant Warning Light ON Article No. 03-25-2 12/22/03 ENGINE - COOLING SYSTEM - LOW COOLANT WARNING INDICATOR LAMP ILLUMINATED COOLANT DEGAS BOTTLE INSPECTION - SERVICE TIP FORD: 2001-2003 ESCAPE This article supersedes TSB 03-08-5 to update the vehicle model years and service procedure. ISSUE Some 2001-2003 Escape 3.0L vehicles may exhibit a low coolant warning indicator lamp illuminated. This may be caused by a low coolant level, even if it appears there is significant coolant in the degas bottle. Analysis of coolant degas bottles indicate that bottle replacement may not be necessary. Adjusting the coolant to the proper level may be all that is required to correct the condition. ACTION The following Service Procedure provides tips to help in veritying proper coolant levels. Additional diagnostic and service information can be found in the appropriate Workshop Manual Section 303-03. SERVICE PROCEDURE PROPER INSPECTION AND ADJUSTMENT OF COOLANT LEVEL IN THE DEGAS BOTTLE There are four (4) different cells within the Escape degas bottle. The front cells of the degas bottle are not a good visual indicator of proper coolant level, as these cells will always give the appearance of being full (Figure 1). The actual COLD FILL RANGE is the larger cell with the fill cap, just below the seam. It can be difficult to see if not properly examined. If the vehicle is HOT when inspecting, the coolant level should be at the bottle seam (minimum) or above the seam by 1/2 inch, well above the LOW mark. When hot, if the coolant level is not at least to the top of the COLD FILL RANGE (seam), there is a possibility of illuminating the low coolant lamp when the vehicle cools down and the coolant is drawn back into the engine cooling system. DIAGNOSIS Engine Hot Or Cold Coolant Warning Indicator Lamp Not Illuminated (OFF): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap and return vehicle to customer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Level Sensor: > 03-25-2 > Dec > 03 > Cooling System - Low Coolant Warning Light ON > Page 2833 Engine Hot Or Cold Coolant Warning Indicator Lamp Illuminated (ON): 1. If the coolant level is found to be below the COLD FILL RANGE (seam) add coolant, tighten pressure cap, verify that the warning lamp turns off after key cycle and return to customer. 2. If the coolant level is verified to be at the top of the COLD FILL RANGE (seam), disconnect the coolant level sensor and verify that the warning lamp turns off. If the lamp does turn off then replace the degas bottle. If the lamp remains on with the sensor disconnected then perform diagnostics on the circuit beyond degas bottle/low coolant sensor. NOTE IT TAKES APPROXIMATELY 25 SECONDS FOR THE LOW COOLANT LAMP TO TURN OFF AFTER THE SENSOR CIRCUIT IS OPENED. (EXAMPLE: WHEN ADDING COOLANT TO A LOW BOTTLE WITH LAMP ON.) NOTE DO NOT REPLACE THE DEGAS BOTTLE UNLESS DIRECTED BY DIAGNOSTICS IN STEP 2. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-08-5 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 2834 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Technical Service Bulletins > Page 2835 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2840 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2841 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperatures Starts to open ...................................................................................................................................... ....................................... 90 - 94 °C (194 - 201 °F) Fully open ........................................................... ...................................................................................................................................... 106 °C (223 °F) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2845 Thermostat: Service and Repair Thermostat-2.0L Zetec Removal and Installation 1. Drain the engine coolant. 2. Remove the three bolts and separate the water outlet adapter from the thermostat housing. 3. NOTE: The thermostat is indexed and must be installed correctly. Remove the thermostat and the O-ring seal. 4. NOTE: Clean and inspect the sealing surfaces. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat housing bolts .................................................................................................................... ...................................................... 20 Nm (15 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 2849 Thermostat Housing: Service and Repair Thermostat Housing-2.0L Zetec Removal and Installation 1. Remove the thermostat. 2. Disconnect the heater hose and position out of the way. 3. Remove the thermostat housing. 4. NOTE: Clean and inspect the sealing surfaces. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water pump pulley bolts ...................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Catalyst and Exhaust Systems The Catalytic Converter and Exhaust systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO 2) and water vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst will be used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD) system strategy in the PCM. Refer to the Catalyst Efficiency Monitor-Federal Test Procedure at the beginning of Section 1 for specific OBD catalyst monitor information. The number of HO2S(s) used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (i.e. LEV, ULEV, PZEV). Refer to (Figure 136) and (Figure 137) for typical HO2S stream locations and naming convention. On most vehicles only two HO2S are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) will be utilized to monitor catalyst efficiency. However, some Partial Zero Emission Vehicles (PZEV) will utilize three HO2S sensors for each engine bank. The stream 1 sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control, the next group of sensors or stream 2 (HO2S12/HO2S22) is utilized to monitor the light-off catalyst and the last group of sensors or stream 3 (HO2S13/HO2S23) is utilized for long term fuel trim control to optimize catalyst efficiency (Fore Aft Oxygen Sensor Control). Currently Ford's PZEV vehicles use only a 4-cylinder engine, so only the Bank 1 HO2S(s) will be utilized. V-Engines In-Line Engines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2858 Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 475 to 575°F (246 to 301°C). A fast light catalyst is a three way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly decrease the conversion efficiency (Figure 138). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. TWC Conversion Efficiency Chart Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of carbon monoxide (CO), unburned hydrocarbons (HCs) and oxides of nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter through another HO2S mounted in the rear exhaust pipe (Figure 139) and then on into the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Note on some Partial Zero Emission Vehicles (PZEV), there will be a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2) and the third (stream 3) is mounted after the light-off catalyst (Figure 140). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2859 Bank 1 Catalyst Two HO2S Configuration Bank 1 Catalyst Three HO2S Configuration Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to the Exhaust System. Three-Way Catalytic Converter The three-way catalytic (TWC) converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2860 the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensors (HO2S) The HO2S provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2861 Catalytic Converter: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2862 Catalytic Converter: Service and Repair Catalytic Converter-2.0L Zetec Removal 1. Remove the heated oxygen sensor (HO2S). 2. Disconnect the exhaust gas recirculation (EGR) tube. 1 Remove the two bolts. 2 Loosen the EGR tube nut. 3. Remove the catalytic converter nuts. ^ Discard the nuts. 4. Remove the catalyst monitor sensor. 5. Remove the bolts and the catalytic converter bracket. 6. Remove the flagnuts and bolts. ^ Discard the flagnuts, springs and bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2863 7. Remove the catalytic converter bracket nuts. 8. Remove the catalytic converter and rear support bracket. ^ Discard the ring seal and gasket. Installation 1. Position the catalytic converter into place and loosely install the two nuts. ^ Install new gasket and ring seal. ^ Install new nuts. 2. Connect the converter outlet to the muffler inlet pipe. 1 Position the rear support bracket and install the washers and nuts. 2 Loosely install the new bolts, springs and flagnuts. 3. Lower the vehicle. 4. Install the third catalytic converter nut and tighten all the nuts. ^ Install a new nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2864 5. Connect the EGR tube and install the bracket bolts. 6. Raise the vehicle. 7. Tighten the converter outlet to the muffler inlet bolts. 8. Tighten the catalytic converter rear support bracket nuts. 9. Install the catalytic converter bracket and bolts. 10. Install the catalyst monitor sensor. 11. Install the HO2S. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold bolts/nuts ................................................................................................................. ..................................................... 16 Nm (12 ft. lbs.) TWC to exhaust manifold nuts ......................... ........................................................................................................................................ 47 Nm (35 ft. lbs.) TWC bracket bolts ....................................................................................................................... ............................................................. 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2868 Exhaust Manifold: Service and Repair Exhaust Manifold Removal 1. Remove the catalytic converter. 2. Lower the vehicle. 3. Remove the oil level indicator and tube bracket bolt. 4. CAUTION: Do not work on the aluminum engine components until the engine is cold or damage may occur. Remove the six bolts and three nuts and remove the exhaust manifold. ^ Discard the gasket. Installation 1. CAUTION: The exhaust manifold sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces. Carefully clean both sealing surfaces. ^ Position a new gasket. 2. Install the exhaust manifold and tighten using the sequence shown. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2869 3. Install the oil level indicator and tube. 4. Install the catalytic converter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust damper nuts ........................................................................................................................... ...................................................... 21 Nm (15 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Exhaust manifold heat shield bolts ........................................................................................................................................................... 10 Nm (89 in. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler to resonator nuts ...................................................................................................................... .................................................... 50 Nm (37 ft. lbs.) TWC to muffler bolts ......................................... ...................................................................................................................................... 40 Nm (30 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2879 Muffler: Service and Repair Muffler-2.0L Removal and Installation 1. Raise and support the vehicle. 2. Remove and discard the nuts and bolts. ^ Discard the gasket. 3. Disconnect the front muffler hanger insulator. 4. Disconnect the rear muffler hanger insulator. 5. Remove the nuts, bolts and the muffler. ^ Discard the gasket ^ Discard the bolts and nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2880 6. If necessary, remove the nuts and the exhaust damper. 7. To install. reverse the removal procedure. ^ Install a new gaskets. ^ Install new nuts and bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair Exhaust Resonator: Service and Repair Resonator 1. Raise and support the vehicle. 2. Remove and discard the nuts. ^ Discard the gasket. 3. Disconnect the resonator from the hanger and remove the resonator. 4. To install, reverse the removal procedure. ^ Install a new gasket. ^ Install new nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 Body Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2905 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2906 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2907 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2908 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2909 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2911 Body Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2912 Body Control Module: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 59-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2913 59-2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2914 59-3 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque Based Electronic Throttle Control (ETC) Overview Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen II electronic throttle body (replaces throttle cable). Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by not coupling the throttle angle to pedal position, which enables various fuel economy schemes and technologies. Background "Why Torque Based ETC" Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM and low manifold vacuum) while still delivering the same torque requested by the driver. It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. It also enables many fuel economy/emission improvement technologies such as: - VCT (deliver same torque during transitions) - Continuously varying Transmission (CVT) - Hybrid Electric Vehicle (HEV) Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: - Eliminate cruise control actuators - Eliminate ISC Bypass actuator - Better airflow range - Packaging (no cable) Electronic Throttle Body The Gen II electronic throttle body (Figure 148) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from hard-stop angle). 4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75 degree). This hard stop is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use plate sealant. The hole in the plate is not required with ETB because the required idle airflow is provided by the plate angle, which also is the reason there is no IAC. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP assembly requires four wires. - 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2918 position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2- (5 V Reference Voltage) - 2- (Signal Return "ground") - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A safe value will be substituted for a faulty signal if two out of the three signals are bad. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2923 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 2924 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2925 View 151-11 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2928 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2929 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accomodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 2932 Engine Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Powertrain Control Module (PCM) cover. 1 Loosen the bolt and disconnect the electrical connector. 2 Remove the nuts and the cover. 3. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2936 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 2939 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 2940 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 2941 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2946 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2947 Fuel Pump Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2948 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2952 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 2955 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 2956 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 2957 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2962 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2963 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2964 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2970 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2971 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2975 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2976 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2977 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Service and Repair Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position (CPP) electrical connector. 2. Remove the CPP locknut and the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2984 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2985 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2986 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2990 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2991 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 2995 Fuel Tank Pressure Sensor: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the rear seat assembly. 3. Remove the fuel tank sending unit access cover. 4. Disconnect the fuel tank pressure sensor electrical connector. 5. Remove the fuel tank pressure sensor. ^ Disconnect the vapor tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 2996 ^ Carry out a leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3000 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3001 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3006 Oxygen Sensor: Harness Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3007 View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 Oxygen Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3028 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3029 Oxygen Sensor: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3030 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3031 Oxygen Sensor: Application and ID In-Line Engines V-Engines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Remove the bolts and the exhaust manifold heat shield. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3034 INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3035 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the catalyst monitor sensor electrical connector. 2. Raise and support the vehicle. 3. Using the special tool, remove the catalyst monitor sensor. NOTE: If necessary, lubricate the catalyst monitor sensor with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the catalyst monitor sensor to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3036 EGO Sensor Wrench Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3065 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3066 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3067 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3068 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3072 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3073 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3074 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3075 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3079 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3080 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3081 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3082 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3083 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3084 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3088 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3093 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3094 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3095 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3096 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3101 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3102 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3106 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3110 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System The Inertia Fuel Shutoff (IFS) switch (Figure 73) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System > Page 3113 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System NATURAL GAS FUEL SYSTEM Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Reset Instructions 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. 4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking natural gas. WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE IFS SWITCH. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Page 3114 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Remove the cowl side trim panel. 1 Remove the pin-type retainers. 2 Remove the nut. 3 Remove the cowl side trim panel. 2. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Disconnect the connector. 2 Remove the screws and the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3118 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3119 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3120 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3121 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3126 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3127 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3128 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3132 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3133 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3134 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL 1. Disconnect the battery ground cable. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3142 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3143 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the air cleaner. 2. Remove the battery tray. 3. Remove the bolt and the intake pipe. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the front sponge seal of the intake pipe is seated on the shroud panel correctly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3157 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications 4-Cyl Firing Order: 1 3 4 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3161 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. ^ Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3169 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and with a twisting-pulling motion, disconnect the ignition wires from the spark plugs. CAUTION: Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. 2. Disconnect the ignition wires from the ignition coil and remove the wires. INSTALLATION 1. Connect the ignition wires to the correct ignition coil terminals. CAUTION: Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. NOTE: ^ Whenever an ignition wire is reinstalled or a new one is installed, apply Silicone Brake Caliper Grease and Dielectric compound to the interior surface of the ignition wire boot. ^ Before installing the ignition wires, inspect the ignition wires for any visible damage; install new ignition wires if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3170 2. Connect the ignition wires to the correct spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap Spark Plug Gap 0.048-0.052 inch (1.22-1.32 mm) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3174 Spark Plug: Service Precautions CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3175 Spark Plug: Application and ID Spark plug cylinders 1 and 3................................................................................................................ ....................................................................AZFS-32F Spark plug cylinders 2 and 4........................... .......................................................................................................................................................AZF S-32FE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3176 Spark Plug: Service and Repair REMOVAL CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. 1. Grasp the spark plug boot firmly and with a twisting-pulling motion remove the spark plug wires from the spark plug. 2. Remove the spark plugs. NOTE: ^ If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs can be used in any cylinder. ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs. INSTALLATION 1. Adjust the plug gap as necessary. NOTE: Clean the spark plugs with a wire brush or a professional spark plug cleaner (follow the manufacture's instructions). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3177 2. Install the spark plugs. NOTE: Apply Anti-Seize Lubricant to the lower three threads of the spark plugs. Do not allow lubricant to contaminate the spark plug electrodes or insulator tips. 3. Connect the spark plug wires to the spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3181 Compression Check: Testing and Inspection Compression Test Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the 0FF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3182 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is at least 75 percent of the highest reading. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve clearance - intake ........................................................................................................................................... 0.11-0.18 mm (0.004331-0.007087 in.) Valve clearance - exhaust .................................................................................................................................... 0.27-0.34 mm (0.0106299-0.0133858 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3186 Valve Clearance: Service and Repair Valve-Valve Clearance, Adjust Special Tool(s) Removal 1. Remove the timing belt. 2. Remove the camshaft alignment tool. 3. NOTE: Measure each valve's clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure each valves clearance and record its location. 4. Remove the camshafts. 5. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3187 Remove the valve tappets from the cylinder head. 6. NOTE: A midrange clearance is the most desirable: ^ intake: 0.15 mm (0.006 in.) ^ exhaust: 0.3 mm (0.012 in.) NOTE: Select tappets using this formula: tappet thickness = measured clearance plus the base tappet thickness minus most desirable thickness. Select tappets and mark installation location. Installation 1. NOTE: Lubricate the valve tappets with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H. Install the valve tappets. 2. Install the camshafts. 3. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet. 4. Install the camshaft alignment tool. 5. Install the timing belt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3192 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3193 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3199 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3200 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3205 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3207 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3208 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 Body Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 Body Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Body Control Module: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 59-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 59-2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 59-3 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 3225 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3229 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3230 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3231 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Service and Repair Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position (CPP) electrical connector. 2. Remove the CPP locknut and the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3238 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3239 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3240 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3247 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3248 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3249 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3250 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 Data Link Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Data Link Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque Based Electronic Throttle Control (ETC) Overview Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen II electronic throttle body (replaces throttle cable). Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by not coupling the throttle angle to pedal position, which enables various fuel economy schemes and technologies. Background "Why Torque Based ETC" Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM and low manifold vacuum) while still delivering the same torque requested by the driver. It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. It also enables many fuel economy/emission improvement technologies such as: - VCT (deliver same torque during transitions) - Continuously varying Transmission (CVT) - Hybrid Electric Vehicle (HEV) Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: - Eliminate cruise control actuators - Eliminate ISC Bypass actuator - Better airflow range - Packaging (no cable) Electronic Throttle Body The Gen II electronic throttle body (Figure 148) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from hard-stop angle). 4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75 degree). This hard stop is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use plate sealant. The hole in the plate is not required with ETB because the required idle airflow is provided by the plate angle, which also is the reason there is no IAC. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP assembly requires four wires. - 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3271 position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2- (5 V Reference Voltage) - 2- (Signal Return "ground") - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A safe value will be substituted for a faulty signal if two out of the three signals are bad. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3276 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3277 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3278 View 151-11 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3281 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3282 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accomodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 3285 Engine Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Powertrain Control Module (PCM) cover. 1 Loosen the bolt and disconnect the electrical connector. 2 Remove the nuts and the cover. 3. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3289 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3290 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3294 Fuel Tank Pressure Sensor: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the rear seat assembly. 3. Remove the fuel tank sending unit access cover. 4. Disconnect the fuel tank pressure sensor electrical connector. 5. Remove the fuel tank pressure sensor. ^ Disconnect the vapor tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3295 ^ Carry out a leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3299 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL VALVE Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The idle air control (IAC) valve assembly (Figure 122) and (Figure 123) controls engine idle speed and provides a dash pot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3300 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 124) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dash pot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3301 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the Idle Air Control (IAC) valve electrical connector. 2. Raise the vehicle. 3. Remove the two bolts and the IAC valve. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Install a new gasket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Information Bus: Specifications Item....................................................................................................................................................... ..............................................................Specification Heat shrink tube overlap....................................................................................................................... ......................................................12.7 mm (0.5 inch) Wire insulation removal length (twist side)...... ..........................................................................................................................................37.2 mm (1.5 inch) Wire insulation removal length (receiving side).......................................................................................................................................19.5 mm (0.75 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Information Bus: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Module Configuration Information Bus: Description and Operation Module Configuration PRINCIPLES OF OPERATION Some modules support the ability to change specified factory configuration settings and preset preference items. The process used to change the settings and customer preference items is module configuration. There are two different methods of module configuration: - programmable module installation (PMI) - customer preference items There are three storage locations for module configuration information. One primary storage location and two secondary (or backup) storage locations. - Primary location is the memory of the specific module. - First backup location is the VID block memory of the powertrain control module (PCM). - Second backup is the As-Built Data Center. During PMI, the diagnostic tool will attempt to extract the module configuration information from the module to be changed, if this is unsuccessful, the diagnostic tool will use the first backup and attempt to extract the module configuration information from the VID block in the PCM. If this also fails, the diagnostic tool will display instructions to contact the As-Built Data Center. This is the only time the As-Built Data Center should be contacted. Programmable Module Installation (PMI) NOTE: If the powertrain control module (PCM) needs to have a powertrain calibration flash programmed, refer to Computers and Control Systems. Make sure to use the flash cable when programming calibrations or running a PMI routine on the PCM. The PMI configuration method is used when a new programmable module is to be installed. During the PMI routine the diagnostic tool attempts to gather two pieces of information: option content information from the old module (module configuration and customer preference settings) - the vehicle identification number (VIN) from the PCM During PMI the diagnostic tool first looks to the PCM for the VIN of the vehicle. Once the VIN is retrieved the diagnostic tool will carry out a self-test of the suspect module to determine if the module has been configured. If DTC B2477 is present the module does not contain complete configuration information. The PMI routine will then halt and give instructions on how to proceed. - If DTC B2477 is not present the module will allow the diagnostic tool to retrieve its option content information. The diagnostic tool will then store the option content information and the VIN. The diagnostic tool can store the combined option content information and VIN for only one module at a time. Once information is stored, the diagnostic tool cannot be used to retrieve any other option content information without erasing the previous option content information. Make sure the new module is on hand for installation before retrieving option content information data from the old module. After the new module is installed, use the diagnostic tool to restore the option content information into the new module. Vehicle Identification (VID) Block NOTE: If the PCM needs to have a powertrain calibration flash programmed, refer to Computers and Control Systems. Make sure to use the flash cable when programming calibrations or running a PMI routine on the PCM. - When carrying out a PMI routine on any non-PCM module, use the OBDII cable. - Flash programming powertrain calibrations onto the PCM is different than PMI. It has no effect on the backup data in the VID block memory area of the PCM. The PCM contains a memory area called a vehicle identification (VID) block. A portion of the VID block is used to store the backup data for each programmable module on the vehicle. The VID block is the first backup of information when using the PMI configuration method. If the diagnostic tool cannot retrieve option content information from the suspect module, the diagnostic tool will attempt to extract backup information from the VID block of the PCM. The VID block is not related to or affected by the powertrain calibration information stored in the PCM. If a new powertrain calibration has been flashed onto the PCM, the VID block will not be affected. If using the PMI routine to install a new PCM, the diagnostic tool will reprogram only VID information. The engine calibration information may still need to be flashed. For more information, refer to Computers and Control Systems for flash programming information. As-Built Data Center The As-Built Data Center keeps a record of the vehicle configuration in a database that is retrievable using the VIN. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center will always reflect the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Module Configuration > Page 3330 original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the diagnostic tool. Customer Preference Items This method is used to enable or disable module-controlled items or systems to suit the preference of the customer. Not all features controlled by the module are listed in this configuration method. Refer to the Module Configuration Index for a list of features for each module. If a feature is changed using the customer preference items configuration method, the changed information will not be stored in the PCM VID block. The VID block will retain the original settings as they were recorded when the vehicle left the factory. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Module Configuration > Page 3331 Information Bus: Description and Operation Communications Network Description and Operation COMMUNICATIONS NETWORK The module communications network consists of the following items: - standard corporate protocol (SCP) communications network - international standards organization (ISO) communications network - generic electronic module (GEM) - powertrain control module (PCM) - anti-lock brake system (ABS) module - restraint control module (RCM) - instrument cluster (IC) Principles of Operation (How Does It Work?) PRINCIPLES OF OPERATION The vehicle has two module communications networks. The standard corporate protocol (SCP) network, which is an unshielded twisted pair cable (data bus plus, circuit 914 [TN/OG] and data bus minus, circuit 915 [PK/LB]); and the international standards organization (ISO) 9141 network which is a single wire (circuit 70 [LB/WH]). The diagnostic tool can connect to both networks through the data link connector (DLC). This makes diagnosis and testing of these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel on the driver side. The SCP communication network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or voltage, or if some, but not all, termination resistors are lost. The ISO 9141 communication network does not permit inter-module communication. When the diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic tool must ask for all information; the modules cannot initiate communications. Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to ground or battery voltage. Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. There are two modules linked to the SCP communication network and three modules linked to the ISO 9141 communication network. The powertrain control module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The passive anti-theft system (PATS) is integrated into the PCM module. The PCM/PATS system is connected to the vehicle electrical system, the transceiver module, the vehicle SCP communications network and the vehicle anti-theft indicator located in the instrument cluster (IC). The PCM module uses a microprocessor to control the system functions as well as illumination of the anti-theft indicator. The illumination command is sent from the PCM through the SCP communications network to the IC, which in turn sends power to the anti-theft indicator. The PCM module microprocessor stores the ignition key codes in non-volatile memory. The PCM and IC modules can be diagnosed through the data link connector. For additional IC information, refer to Instrument Panel, Gauges and Warning Indicators. The restraint control module (RCM) is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. The generic electronic module (GEM) is on the ISO 9141 communication network. The GEM controls a variety of systems: - rear wiper - cargo lamps - interior lamps - exterior lamps - accessory delay - perimeter anti-theft (if equipped) For additional GEM information, refer to Multifunction Electronic Control Module (General Module). The anti-lock brake system (ABS) control module is on the ISO 9141 communication network. The ABS module controls the brake pressure to the four wheels to keep the vehicle under control while braking. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network Information Bus: Testing and Inspection Communications Network Initial Inspection INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) Fuse ROOM (10A) - Wiring harness - Connectors - Instrument cluster (IC) - Anti-lock brake system (ABS) control module - Restraint control module (RCM) - Generic electronic module (GEM) - Powertrain control module (PCM) 3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position is in RUN. If the diagnostic tool still dues not communicate with the vehicle, go to Pinpoint Test H. See: Pinpoint Tests/Pinpoint Tests/Test H 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) Pinpoint Test PC (Precheck) PINPOINT TEST PC: DATA LINK DIAGNOSTICS NETWORK TEST Test PC1 Test A PINPOINT TEST A: THE ANTI-LOCK BRAKE SYSTEM (ABS) CONTROL MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3334 Test A1-A3 Test B PINPOINT TEST B: THE RESTRAINT CONTROL MODULE (RCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3335 Test B1-B3 Test C PINPOINT TEST C: THE GENERIC ELECTRONIC MODULE (GEM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Test C1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3336 Test C2-C3 Test D PINPOINT TEST D: THE INSTRUMENT CLUSTER (IC) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Test D1-D2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3337 Test D2-D3 Test E PINPOINT TEST E: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Test E1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3338 Test E2-E3 Test F PINPOINT TEST F: NO MODULE/NETWORK COMMUNICATION - ISO 9141 NETWORK Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3339 Test F1-F5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3340 Test F5-F10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3341 Test F11-F12 Test G PINPOINT TEST G: NO MODULE/NETWORK COMMUNICATION - SCP NETWORK Test G1-G4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3342 Test G5-G8 Test H PINPOINT TEST H: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC TOOL Test H1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3343 Test H2-H4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3344 Symptom Chart, Part 1 Symptom Chart, Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3345 Information Bus: Testing and Inspection Module Configuration Initial Inspection INSPECTION AND VERIFICATION 1. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Damaged wiring harness - Loose or corroded connectors - Instrument cluster (IC) - Generic electronic module (GEM) - Powertrain control module (PCM) 2. If the concern remains after inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check that the ignition switch is in the RUN position. 3. If the diagnostic tool still does not communicate with the vehicle, refer to Module Communications Network (Information Bus). 4. Refer to the Symptom Chart. See: Diagnosis By Symptom Module Configuration Index MODULE CONFIGURATION INDEX Module Configuration Index NOTE: Do not contact the As-Built Data Center unless the diagnostic tool instructs you to do so. The diagnostic tool will not allow you to use as-built data information unless the diagnostic tool first prompts you for the As-Built Data Center information. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3346 Diagnostic Tool Message Index, Part 1 Diagnostic Tool Message Index, Part 2 Pinpoint Tests PINPOINT TEST A: UNABLE TO CONFIGURE THE NEW MODULE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Communications Network > Page 3347 Test A1-A2 Test A3-A4 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service and Repair > Communication Circuit Wiring Repair Information Bus: Service and Repair Communication Circuit Wiring Repair COMMUNICATION CIRCUIT WIRING REPAIR Heat Gun SPECIAL TOOL(S) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. NOTE: Use rosin core mildly activated (RMA) solder, not acid core solder. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service and Repair > Communication Circuit Wiring Repair > Page 3350 4. NOTE: Wait for the solder to cool before moving the wires. Bend the wires back in a straight line. 5. Position the (A) heat shrink tube over the (B) wire repair. - Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service and Repair > Communication Circuit Wiring Repair > Page 3351 Information Bus: Service and Repair Module Configuration Programmable Module Installation PROGRAMMABLE MODULE INSTALLATION NOTE: If using the WDS, select Module Configuration and Programming, then follow the screen prompts. - Do not remove the original module from the vehicle until the diagnostic tool has retrieved the module's configuration information. - Make sure the module is listed as being supported by programmable module installation in the Module Configuration Index. - Make sure to use the flash cable when programming calibrations or running a PMI routine on the PCM. - It is important to keep a record of any error message given by the tester during the programmable module installation routine. Additionally, observe the point during the routine that the error message is given and refer to the Diagnostic Tool Message Index. This will help determine what is causing the error message. 1. Select Programmable Module Installation on the diagnostic tool. 2. Select Retrieve Module Configuration - Old ECU, and follow the text screens until successful. 3. Install the new module. 4. Continue with directions from the diagnostic tool for module reprogramming. Programmable Module Installation - Using Backup Data PROGRAMMABLE MODULE INSTALLATION - USING BACKUP DATA NOTE: If using the WDS, select Module Configuration and Programming then follow the screen prompts. - Make sure to use the flash cable when programming calibrations or running a PMI routine on the PCM. 1. Select Programmable Module Installation on the diagnostic tool. 2. Select Retrieve Module Configuration - Old ECU. The diagnostic tool will give you a message to reinstall the old module or to continue for backup data. If the module to be replaced will not communicate or has incorrect data, continue and allow the diagnostic tool to find backup data. If the diagnostic tool successfully retrieves the backup data, GO to Step 7 in this procedure. If the diagnostic tool prompts you to contact the As-Built Data Center for backup information, contact the As-Built Data Center and obtain the backup data for the vehicle and continue on. 3. After the As-Built Data Center backup data is obtained continue with the routine by entering the VIN number of the vehicle when the diagnostic tool prompts you to do so. 4. The diagnostic tool will prompt you to enter the vehicle data. The vehicle data is listed on the As-Built Data Center sheet in the upper left-hand portion, directly underneath the VIN for the vehicle. 5. The diagnostic tool will prompt you to enter information for the module that needs to be reprogrammed. Enter all of the data that the diagnostic tool requests. If the diagnostic tool requests information that is not listed on the As-Built Data Center sheet, press NO. 6. Follow the text screens until all pertinent data is entered and the module data is stored. 7. Select Restore Module Configuration - New ECU, and follow the text screens until successful. 8. Manually validate each customer preference item for correct setting. If necessary, ask the customer what setting would be their preference. Refer to the Module Configuration Index for the list of customer preference items. Customer Preference Items CUSTOMER PREFERENCE ITEMS NOTE: If using the WDS, select Module Configuration and Programming, then follow the screen prompts. - Make sure module is listed as supporting customer preference items and supports the specific item to be configured in the Module Configuration Index. 1. Select Service Bay Functions on the diagnostic tool. 2. Select the module that contains the customer preference item to be programmed. Refer to the Module Configuration Index. 3. Select Customer Preference Items on the diagnostic tool. 4. Select Module Option Content. 5. Select the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the customer preference. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service and Repair > Page 3352 Information Bus: Tools and Equipment Special Tool(s) Heat Gun Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3356 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3357 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3361 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3364 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3365 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3366 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) (Figure 17) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 18). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Malfunction Indicator Lamp (MIL) CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3374 Oxygen Sensor: Harness Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3375 View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 Oxygen Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 Oxygen Sensor: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3399 Oxygen Sensor: Application and ID In-Line Engines V-Engines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Remove the bolts and the exhaust manifold heat shield. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3402 INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3403 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the catalyst monitor sensor electrical connector. 2. Raise and support the vehicle. 3. Using the special tool, remove the catalyst monitor sensor. NOTE: If necessary, lubricate the catalyst monitor sensor with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the catalyst monitor sensor to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3404 EGO Sensor Wrench Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3433 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3434 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3435 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3436 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Body Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 Body Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Body Control Module: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 59-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 59-2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 59-3 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation Torque Based Electronic Throttle Control (ETC) Overview Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen II electronic throttle body (replaces throttle cable). Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by not coupling the throttle angle to pedal position, which enables various fuel economy schemes and technologies. Background "Why Torque Based ETC" Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM and low manifold vacuum) while still delivering the same torque requested by the driver. It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. It also enables many fuel economy/emission improvement technologies such as: - VCT (deliver same torque during transitions) - Continuously varying Transmission (CVT) - Hybrid Electric Vehicle (HEV) Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: - Eliminate cruise control actuators - Eliminate ISC Bypass actuator - Better airflow range - Packaging (no cable) Electronic Throttle Body The Gen II electronic throttle body (Figure 148) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from hard-stop angle). 4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75 degree). This hard stop is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use plate sealant. The hole in the plate is not required with ETB because the required idle airflow is provided by the plate angle, which also is the reason there is no IAC. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP assembly requires four wires. - 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3469 position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2- (5 V Reference Voltage) - 2- (Signal Return "ground") - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A safe value will be substituted for a faulty signal if two out of the three signals are bad. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 3474 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 3475 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3476 View 151-11 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3479 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3480 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accomodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 3483 Engine Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Powertrain Control Module (PCM) cover. 1 Loosen the bolt and disconnect the electrical connector. 2 Remove the nuts and the cover. 3. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3487 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3490 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3491 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3492 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3497 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3498 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3502 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3503 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3504 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Service and Repair Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position (CPP) electrical connector. 2. Remove the CPP locknut and the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3511 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3512 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3513 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3517 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3518 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the generator. 2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3522 Fuel Tank Pressure Sensor: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the rear seat assembly. 3. Remove the fuel tank sending unit access cover. 4. Disconnect the fuel tank pressure sensor electrical connector. 5. Remove the fuel tank pressure sensor. ^ Disconnect the vapor tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3523 ^ Carry out a leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3527 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3528 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3533 Oxygen Sensor: Harness Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3534 View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Oxygen Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Oxygen Sensor: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3558 Oxygen Sensor: Application and ID In-Line Engines V-Engines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Remove the bolts and the exhaust manifold heat shield. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3561 INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3562 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor EGO Sensor Wrench SPECIAL TOOL(S) REMOVAL 1. Disconnect the catalyst monitor sensor electrical connector. 2. Raise and support the vehicle. 3. Using the special tool, remove the catalyst monitor sensor. NOTE: If necessary, lubricate the catalyst monitor sensor with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to aid in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the catalyst monitor sensor to aid in installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3563 EGO Sensor Wrench Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3586 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3587 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3592 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3593 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3594 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3595 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3599 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3600 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3601 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3602 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3606 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3607 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3608 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3609 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3610 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3611 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3615 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3619 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3620 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3621 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3622 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3626 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3627 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3628 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3629 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3630 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3631 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded. The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A intake phase shifting system will move the intake cam in the advance direction. The other two possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module (PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems have the added benefit of improve torque. In addition a VCT system will eliminate the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Increased vehicle reliability is achieved with the elimination of the EGR system. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control module) with crankshaft positioning information in 10 degree increments (Figure 130). 1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant temperature), CMP, TP (throttle position), MAF (Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. 5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear piston motion to a rotational motion that advances or retards the camshaft. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 3635 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty near 50%. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The VCT unit assembly (Figure 132) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, a pressure differential occurs forcing the piston to move. This movement is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3639 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information > Description and Operation Air Injection: Description and Operation SECONDARY AIR INJECTION (AIR) SYSTEMS Overview The Secondary Air Injection (AIR) system controls emissions during the first 20 to 120 seconds of engine operation by forcing air downstream into the exhaust manifolds to oxidize the hydrocarbons and carbon monoxide created by running rich at start up. Electric Secondary Air Injection System Dual Or Single AIRD Valve Electric Secondary Air Injection (AIR) The Electric Secondary Air Injection (AIR) system consists of an Electric AIR Pump (EAP), single or dual combination check air injection diverter (AIR diverter) valve(s), an AIR bypass solenoid, a solid state relay, Powertrain Control Module (PCM) and connecting wires and vacuum hoses. 1. The PCM requires Engine Coolant Temperature (ECT), Intake Air Temperature (IAT) and Crankshaft Position (CKP) inputs to initiate Secondary Air Injection function. 2. When the engine is started, the strategy will determine when to enable the EAP. The PCM signals the solid state relay and the AIR bypass solenoid, after a (5 to 10) second delay, to begin system operation. Once the catalyst is lit-off, the PCM then signals the solid state relay to stop AIR pump operation and to close the AIR bypass solenoid from supplying vacuum to the AIR diverter valve(s). 3. The solid state relay provides the start-up signal and will switch the high current required to operate the AIR pump. 4. The AIR bypass solenoid applies a vacuum to the AIR diverter valve(s) causing it to open and to allow air to flow into the exhaust manifolds. 5. The vacuum check valve controls vacuum bleed-off to solenoid. 6. The function of the splash cap if equipped is to provide the AIR pump with a source of dry air. 7. The electric AIR pump delivers the required amount of air to control emissions during engine operation. Air is forced into the exhaust manifolds to oxidize the hydrocarbons and carbon monoxide created by running rich at start up. Hardware Electric AIR Pump Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information > Description and Operation > Page 3644 Electric Air Pump The electric AIR pump provides pressurized air to the Secondary Air Injection system. The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The inlet system of the AIR pump incorporates a non-serviceable filter and splash cap which helps to guard against dirt and water. AIR Bypass Solenoid Secondary Air Injection Bypass Solenoid The secondary air injection bypass (AIR bypass) solenoid is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit vacuum release. AIR Diverter Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information > Description and Operation > Page 3645 Air Injection Diverter (AIR Diverter) Valve The secondary air injection diverter (AIR diverter) valve is used with the electric AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System. Solid State Relay Solid State Relay The solid state relay switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the powertrain control module (PCM). Vacuum Check Valves Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information > Description and Operation > Page 3646 Vacuum Check Valve A vacuum check valve blocks air flow in one direction. It allows free air flow in the other direction. The check side of this valve will hold the highest vacuum registered on the vacuum side. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation Catalyst and Exhaust Systems The Catalytic Converter and Exhaust systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO 2) and water vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst will be used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD) system strategy in the PCM. Refer to the Catalyst Efficiency Monitor-Federal Test Procedure at the beginning of Section 1 for specific OBD catalyst monitor information. The number of HO2S(s) used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (i.e. LEV, ULEV, PZEV). Refer to (Figure 136) and (Figure 137) for typical HO2S stream locations and naming convention. On most vehicles only two HO2S are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) will be utilized to monitor catalyst efficiency. However, some Partial Zero Emission Vehicles (PZEV) will utilize three HO2S sensors for each engine bank. The stream 1 sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control, the next group of sensors or stream 2 (HO2S12/HO2S22) is utilized to monitor the light-off catalyst and the last group of sensors or stream 3 (HO2S13/HO2S23) is utilized for long term fuel trim control to optimize catalyst efficiency (Fore Aft Oxygen Sensor Control). Currently Ford's PZEV vehicles use only a 4-cylinder engine, so only the Bank 1 HO2S(s) will be utilized. V-Engines In-Line Engines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3650 Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 475 to 575°F (246 to 301°C). A fast light catalyst is a three way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly decrease the conversion efficiency (Figure 138). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. TWC Conversion Efficiency Chart Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of carbon monoxide (CO), unburned hydrocarbons (HCs) and oxides of nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter through another HO2S mounted in the rear exhaust pipe (Figure 139) and then on into the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Note on some Partial Zero Emission Vehicles (PZEV), there will be a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2) and the third (stream 3) is mounted after the light-off catalyst (Figure 140). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3651 Bank 1 Catalyst Two HO2S Configuration Bank 1 Catalyst Three HO2S Configuration Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to the Exhaust System. Three-Way Catalytic Converter The three-way catalytic (TWC) converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3652 the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensors (HO2S) The HO2S provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3653 Catalytic Converter: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3654 Catalytic Converter: Service and Repair Catalytic Converter-2.0L Zetec Removal 1. Remove the heated oxygen sensor (HO2S). 2. Disconnect the exhaust gas recirculation (EGR) tube. 1 Remove the two bolts. 2 Loosen the EGR tube nut. 3. Remove the catalytic converter nuts. ^ Discard the nuts. 4. Remove the catalyst monitor sensor. 5. Remove the bolts and the catalytic converter bracket. 6. Remove the flagnuts and bolts. ^ Discard the flagnuts, springs and bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3655 7. Remove the catalytic converter bracket nuts. 8. Remove the catalytic converter and rear support bracket. ^ Discard the ring seal and gasket. Installation 1. Position the catalytic converter into place and loosely install the two nuts. ^ Install new gasket and ring seal. ^ Install new nuts. 2. Connect the converter outlet to the muffler inlet pipe. 1 Position the rear support bracket and install the washers and nuts. 2 Loosely install the new bolts, springs and flagnuts. 3. Lower the vehicle. 4. Install the third catalytic converter nut and tighten all the nuts. ^ Install a new nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3656 5. Connect the EGR tube and install the bracket bolts. 6. Raise the vehicle. 7. Tighten the converter outlet to the muffler inlet bolts. 8. Tighten the catalytic converter rear support bracket nuts. 9. Install the catalytic converter bracket and bolts. 10. Install the catalyst monitor sensor. 11. Install the HO2S. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3661 Canister Purge Control Valve: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3662 Canister Purge Control Valve: Description and Operation EVAP CANISTER PURGE VALVE EVAP Canister Purge Valve EVAP Canister Purge Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3663 Electronic EVAP Canister Purge Valve The EVAP canister purge valve (Figure 100) and (Figure 101) is part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. The electronic EVAP canister purge valve (Figure 102) controls the flow of vapors electronically by way of a solenoid thereby, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3664 Canister Purge Control Valve: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Disconnect the EVAP canister purge valve. ^ Disconnect the electrical connector. ^ Disconnect the vacuum tube. ^ Disconnect the EVAP canister outlet tube. ^ Disconnect the EVAP return tube. 3. Remove the EVAP canister purge valve. ^ Remove the two nuts. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL (R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions Evaporative Canister Filter: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions > Page 3668 Evaporative Canister Filter: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. 3. Disconnect the EVAP canister outlet tube. 4. Disconnect the canister vent solenoid electrical connector and the remote canister vent hose. 5. Remove the EVAP canister bracket assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions > Page 3669 6. Remove the remote canister vent hose. 7. Remove the dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL (R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions Evaporative Emission Control Canister: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions > Page 3673 Evaporative Emission Control Canister: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. 3. Disconnect the EVAP canister outlet tube. 4. Disconnect the canister vent solenoid electrical connector and the remote canister vent hose. 5. Remove the EVAP canister bracket assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service Precautions > Page 3674 6. Remove the remote canister vent hose, dust separator and canister vent solenoid. 7. Remove the EVAP canister outlet tube. 8. Remove the EVAP canister. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL (R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3678 Leak Detection Valve: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3679 Leak Detection Valve: Description and Operation CANISTER VENT SOLENOID Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the canister vent (CV) solenoid (Figure 105) seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3680 Leak Detection Valve: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. 3. Disconnect the EVAP canister outlet tube. 4. Disconnect the canister vent solenoid electrical connector and the remote canister vent hose. 5. Remove the EVAP canister bracket assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3681 6. Remove the remote canister vent hose and the dust separator. 7. Remove the canister vent solenoid. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission Repair Verification Drive Cycle NOTE: Lubricate all O-ring seals with MERPOL(R) O-Ring Seal Lubricant meeting Ford specification ESE-M99B144-B or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation ON-BOARD REFUELING VAPOR RECOVERY (ORVR) EVAPORATIVE EMISSION (EVAP) SYSTEM On-Board Refueling Vapor Recovery Evaporative Emission System On-Board Refueling Vapor Recovery Evaporative Emission System Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Page 3685 On-Board Refueling Vapor Recovery Evaporative Emission System The basic elements forming the ORVR system (Figure 107), (Figure 108) and (Figure 109) operation are as follows when fuel is dispensed: 1. The fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank, while liquid is entering the fuel tank (liquid in the one inch diameter tube blocks vapors from rushing back up the fuel filler pipe). 2. A fuel vapor control valve controls the flow of vapors out of the fuel tank (valve closes when liquid level reaches a height associated with the fuel tank usable capacity). This valve accomplishes the following: a. Limits the total amount of fuel that can be dispensed into the fuel tank. b. Prevents liquid gasoline from exiting the fuel tank when submerged (and also when tipped well beyond a horizontal plane as part of the vehicle roll-over protection in road accidents). c. Minimizes vapor flow resistance during anticipated refueling conditions. 3. Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the fuel tank vapors (displaced by the incoming liquid) to the EVAP canister. 4. A check valve in the bottom of the fuel filler pipe prevents liquid from rushing back up the fuel filler pipe during the liquid flow variations associated with the filler nozzle shut-off. Between refueling events, the EVAP canister is purged with fresh air so that it may be used again to store vapors accumulated during engine soaks or subsequent refueling events. The vapors drawn off of the carbon in the EVAP canister are consumed in the engine. Refer to Evaporative Emissions System for information on the following Evaporative Emission System components: liquid/vapor fuel discriminator, fuel filler pipe check valve, fill limit valve assembly, fill limit vent valve assembly, fuel filler pipe flapper valve, fuel vapor control valve (fuel tank mounted), ORVR T-connector assembly and EVAP canister. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 3690 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR VACUUM REGULATOR SOLENOID EVR Solenoid Test Graph EGR Vacuum Regulator Solenoid Data Chart The EGR Vacuum Regulator Solenoid (EVR), (Figure 90) is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 3691 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the EGR vacuum regulator valve. ^ Disconnect the electrical connector. ^ Disconnect the vacuum hoses. 3. Remove the nuts and remove the EGR vacuum regulator solenoid. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service Precautions EGR Tube: Service Precautions CAUTION: ^ When the EGR tube is disconnected from the EGR valve a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected, and a new EGR valve installed if the threads are damaged. ^ The EGR tube must be discarded after removal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service Precautions > Page 3695 EGR Tube: Description and Operation ORIFICE TUBE ASSEMBLY Orifice Tube Assembly The orifice tube assembly (Figure 92) is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service Precautions > Page 3696 EGR Tube: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the splash shield. 3. Disconnect the EGR tube fitting. 4. Lower the vehicle. 5. Remove the air cleaner outlet pipe. 6. Disconnect the EGR tube from the EGR valve. CAUTION: When the EGR tube is disconnected from the EGR valve a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected, and a new EGR valve installed if the threads are damaged. 7. Remove the EGR tube bracket bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service Precautions > Page 3697 8. Carefully remove the differential pressure feedback EGR sensor from the EGR tube. 9. Remove and discard the EGR tube. CAUTION: The EGR tube must be discarded after removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service Precautions EGR Valve: Service Precautions CAUTION: When the EGR tube is disconnected from the EGR valve a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected and a new EGR valve installed if the threads are damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service Precautions > Page 3701 EGR Valve: Description and Operation EXHAUST GAS RECIRCULATION VALVE EGR Valve The EGR valve (Figure 91) in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service Precautions > Page 3702 EGR Valve: Service and Repair REMOVAL 1. Remove and discard the exhaust manifold to EGR valve tube. 2. Remove the air cleaner outlet pipe. 3. Remove the EGR valve. 1 Disconnect the vacuum line. 2 Remove the bolts. CAUTION: When the EGR tube is disconnected from the EGR valve a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected and a new EGR valve installed if the threads are damaged. INSTALLATION 1. To install, reverse the removal procedure. ^ Carefully clean all sealing surfaces and install a new EGR valve gasket. NOTE: The EGR valve sealing surfaces are soft metals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3706 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3707 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3708 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3709 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil Separator > Component Information > Service and Repair Oil Separator: Service and Repair REMOVAL 1. Remove the three way catalytic convertor. 2. Remove the crankcase vent oil separator. 1 Disconnect the Positive Crankcase Ventilation (PCV) valve. 2 Remove the bolts and remove the separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Carefully clean all sealing surfaces and install a new crankcase vent oil separator gasket. NOTE: The oil separator sealing surfaces are soft metal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair REMOVAL 1. Disconnect the crankcase ventilation tube from the Positive Crankcase Ventilation (PCV) valve. 2. Disconnect the hose from the tube. 3. Unclip the crankshaft position sensor wiring harness. 4. Remove the thermostat housing. 5. Remove the bolt from the tube bracket and remove the tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair Positive Crankcase Ventilation Valve: Service and Repair REMOVAL 1. Remove the PCV valve. ^ Remove the crankcase ventilation hose from the PCV valve. ^ Remove the PCV valve from the grommet by turning the valve counter-clockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3724 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3725 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 88) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3726 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 89) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations > Page 3727 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback EGR sensor. 1 Disconnect the electrical connector. 2 Carefully remove the differential pressure feedback EGR sensor by sliding up and off the EGR tube. NOTE: The 3.0L (4V) engine is shown, the 2.0L Zetec engine is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3736 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Technician Safety Information Accelerator Pedal: Technician Safety Information WARNING: MAKE SURE SURROUNDING COMPONENTS SUCH AS WIRING, HOSES, SOUND INSULATION AND FLOOR CARPETING ARE NOT CONTACTING THE SLIDING INNER CABLE OF THE ACCELERATOR CABLE OR THE ACCELERATOR PEDAL AND SHAFT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Technician Safety Information > Page 3742 Accelerator Pedal: Vehicle Damage Warnings CAUTION: Do not pull the accelerator cable out by the cable housing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Page 3743 Accelerator Pedal: Description and Operation The acceleration control consists of the pedal and shaft assembly, accelerator cable and accelerator cable bracket. WARNING: MAKE SURE SURROUNDING COMPONENTS SUCH AS WIRING, HOSES, SOUND INSULATION AND FLOOR CARPETING ARE NOT CONTACTING THE SLIDING INNER CABLE OF THE ACCELERATOR CABLE OR THE ACCELERATOR PEDAL AND SHAFT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft. The accelerator pedal and shaft should travel smoothly from the idle to the wide-open throttle positions. Hesitation on return or prevention of return to the idle position must not occur. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview Verify the condition by operating the accelerator pedal and shaft from idle to wide open-throttle and back again. Check for any resistance in forward travel of the accelerator pedal and shaft or hesitation on return. If a concern exists, visually inspect all components of the accelerator pedal and shaft. Look for damage or binding of the accelerator cable. Look for obstructions at the throttle body and accelerator pedal and shaft. For vehicles equipped with speed control, examine the speed control cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3746 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft Accelerator Pedal: Service and Repair Accelerator Pedal and Shaft REMOVAL 1. Disconnect the accelerator cable from the throttle lever and bracket. 2. Remove the accelerator pedal and shaft assembly. 1 Disconnect the accelerator cable. 2 Remove the bolts. INSTALLATION 1. To install, reverse the removal procedure. NOTE: To ease installation, remove the grommet from the throttle lever and install it onto the accelerator cable end. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal and Shaft > Page 3749 Accelerator Pedal: Service and Repair Cable REMOVAL 1. Disconnect the accelerator cable from the throttle lever and bracket. 1 Disconnect the accelerator cable from the throttle lever. 2 Disconnect the accelerator cable from the bracket. 2. Disconnect the accelerator cable from the pedal. 3. Remove the accelerator cable. 1 Remove the bracket bolt. 2 Discount the accelerator cable from the air cleaner outlet tube. 3 Remove the accelerator cable from the dash panel. CAUTION: Do not pull the accelerator cable out by the cable housing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: To ease installation, remove the grommet from the throttle lever and install it onto the accelerator cable end. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the air cleaner. 2. Remove the battery tray. 3. Remove the bolt and the intake pipe. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the front sponge seal of the intake pipe is seated on the shroud panel correctly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3757 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3758 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Capacity Specifications Fuel: Capacity Specifications Fuel Tank Capacity Fuel Tank Capacity 16 Gallons (61 L) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Capacity Specifications > Page 3763 Fuel: Fluid Type Specifications Fuel Type Fuel Type 87 Octane Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cut Valve Solenoid (CNG) > Component Information > Description and Operation Fuel Cut Valve Solenoid (CNG): Description and Operation NATURAL GAS FUEL SYSTEM Fuel Tank Shutoff Valve Fuel Tank Shutoff Valve The fuel tank shutoff solenoid valve (Figure 84) is located in the fuel tank. The solenoid valves are on the same circuit as the gasoline fuel pump and utilize the same Inertia fuel shutoff (IFS) switch as gasoline. When the key is in the off position, the shutoff valves are closed and fuel in the tanks is isolated. During refueling, the shutoff valve acts as a check valve and allows flow due to pressure differential between the fuel being added from the fill station and the fuel in the tank. The internal solenoid valves also have the capability of being "manually locked down." If, while servicing the vehicle, it becomes necessary to remove the fuel tank, the lock down feature provides an added measure of safety. In addition, the valve has an internal Canadian Gas Association (CGA) type 9 fusible link Pressure Relief Device (PRD) that senses the internal fuel tank gas temperature. The contents in the tank are vented when the internal fuel tank gas temperature reaches 199°C (217°F) and melts the fusible link. The escaping gas is vented through a vent line to the atmosphere. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3775 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3776 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3777 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3778 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3779 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3785 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3786 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3787 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3788 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3789 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Gasoline Fuel System Fuel Filler Cap: Description and Operation Gasoline Fuel System FUEL FILLER CAP Fuel Filler Cap The fuel filler cap (Figure 106) is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. Some vehicles may have a Fuel Cap On Indicator Lamp (FCIL) in the instrument cluster which will illuminate when there is a failure in the vapor management system that may be due to the fuel filler cap not being sealed. Refer to the individual component for information on the following Evaporative Emission System components: fuel vapor control valve, fuel vapor vent valve assembly and fuel vapor separator assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Gasoline Fuel System > Page 3792 Fuel Filler Cap: Description and Operation Natural Gas Fuel System NATURAL GAS FUEL SYSTEM Fueling Connector Flange Assembly-Fuel Tank Fill Flange Assembly The flange assembly (Figure 83) is designed for 20,685 kPa (3,000 psi) service pressure and is the refueling connection to fill the vehicle. The assembly is mounted behind the fuel filler door and attached to the fuel filler housing, similar to a gasoline vehicle. This assembly consists of an NGVP1 type receptacle with a 150 micron filter (which can be serviced), a spring loaded check valve to allow filling of the vehicle and a manually opened bypass to provide safe venting of the fuel system. The vehicle is refueled by attaching the fuel station fill nozzle to the receptacle and locking into place. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3797 Fuel Pressure Release: Service and Repair 1. Remove the LH engine compartment relay panel cover. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE REPAIRING OF THE FUEL SYSTEM HAS BEGUN. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Before disconnecting any fuel tube, release the fuel pressure from the fuel system. 2. Remove the fuel pump relay. 3. Start the engine. 4. After the engine stalls, crank the engine over two more times to be sure all the pressure has been released. 5. Turn the ignition switch to the OFF position. Install the fuel pump relay. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions Fuel Injector Wiring Harness: Service Precautions 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 3802 Fuel Injector Wiring Harness: Service and Repair REMOVAL 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the air cleaner outlet pipe. 2. Disconnect the following electrical connectors: 1 cylinder temperature sensor 2 throttle position sensor 3 wiring harness to vehicle 4 idle air control valve 5 camshaft position sensor 6 crankshaft position sensor 7 ignition coil 8 radio ignition noise suppressor 9 fuel injectors 3. Disconnect the wiring harness to vehicle connectors from bracket and remove harness. NOTE: Remove and reinstall new tie straps if necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information Fuel Line Coupler: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information > Page 3807 Fuel Line Coupler: Vehicle Damage Warnings CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings Fuel Line Coupler: Service and Repair Push Connect Fittings Disconnect 1. Relieve the fuel pressure. WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL- RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Disconnect the battery ground cable. 3. Separate the coupling. 1 Depress the tabs 2 Separate the coupling. Connect 1. Clean and inspect the coupling and the tube for damage. 2. Align the tube to the coupling and push until you hear a click. 3. Pull on the coupling to make sure it is fully engaged. 4. Connect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3810 Fuel Line Coupler: Service and Repair R-Clip Fittings Disconnect WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. 2. Disconnect the battery ground cable. 3. Remove the shipping tab by bending downward. 4. Spread the R-clip legs and push the clip into the fitting. 5. Separate the fitting from the tube. Connect 1. Clean and inspect the fitting and the tube for damage. Remove any foreign material or obstructions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3811 2. Insert the R-clip into the fitting. 3. Align the tube and the fitting. 4. Insert the tube in the fitting and push together until a click is heard. 5. Pull on the connection to make sure it is fully engaged. 6. Connect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3812 Fuel Line Coupler: Service and Repair Spring Lock Couplings Fuel Pipe 1/2 Inch Remover (Green) SPECIAL TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Relieve the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the fuel line clip. 4. Install the special tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3813 5. Close and push the special tool into the open side of the cage. 6. Separate the coupling. 7. Remove the special tool. CONNECT 1. Clean and inspect both coupling ends. Install new O-ring seals and garter springs if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3814 2. Fit the male coupling into the female end and push until the garter spring snaps over the flared end of the female coupling. 3. Verify coupling engagement by pulling on the lines. 4. Install the fuel line clip. 5. Connect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 3815 Fuel Line Coupler: Service and Repair Vapor Tube Fittings DISCONNECT 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Clean and inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. 5. Connect the battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3816 Fuel Pipe 1/2 Inch Remover (Green) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Gasoline Fuel System Fuel Pressure Regulator: Description and Operation Gasoline Fuel System FUEL PRESSURE REGULATOR Fuel Pressure Regulator The fuel pressure regulator (Figure 72) is attached to the fuel rail downstream of the fuel injectors. It regulates fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel tank. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Gasoline Fuel System > Page 3821 Fuel Pressure Regulator: Description and Operation Natural Gas Fuel System FUEL PRESSURE REGULATOR Fuel Pressure Regulator The fuel pressure regulator (Figure 80) used in the Natural Gas fuel system is a single-stage pressure reducing regulator which expands natural gas from storage pressures of 1,379 to 20,685 kPa (200 to 3,000 psig) to engine fuel injector pressures of 724 to 862 kPa (105 to 125 psig) The regulator contains a pressure relief device, a 1,896 kPa (275 psig) check valve, which protects the low pressure fuel system. The low pressure fuel system no longer must fulfill the design requirements of the high pressure fuel system, therefore reducing cost, weight and complexity. When gas expands, the fuel temperature drops significantly causing extreme cold temperatures (-177°C or -160°F) that may damage synthetic fuel system components as well as cause water vapor within the fuel to condense, freeze and plug the lines, valve and injectors. To prevent this, engine coolant is routed through the fuel pressure regulator to warm the fuel before it expands. The regulator has an internal thermostat to control the flow of engine coolant. This prevents overheating and subsequent thinning of the fuel which may cause lean combustion. Outlet coolant flow is restricted by the thermostat when it rises above approximately 82°C (100°F). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3825 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Pulsation Damper: Technician Safety Information 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information > Page 3833 Fuel Pressure Pulsation Damper: Vehicle Damage Warnings CAUTION: ^ Use an O-ring seal made of fuel-resistant material. Use of incorrect O-ring seals may result in fuel leakage. Do not reuse the O-ring seal. ^ Never use silicone grease. Silicone grease may clog the fuel injectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 3834 Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER Pulse Damper The fuel rail pulse damper (Figure 73) located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 3835 Fuel Pressure Pulsation Damper: Service and Repair REMOVAL 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Relieve the fuel system pressure. 2. Remove the fuel pulse damper. 1 Disconnect the vacuum line. 2 Remove the bolts and the damper. 3. Inspect the O-ring seal and install a new seal if damaged. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: ^ Use an O-ring seal made of fuel-resistant material. Use of incorrect O-ring seals may result in fuel leakage. ^ Never use silicone grease. Silicone grease may clog the fuel injectors. NOTE: Lubricate the O-ring seal with clean Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to aid installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3844 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3845 Fuel Pump Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3846 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information Fuel Rail: Technician Safety Information 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information > Page 3851 Fuel Rail: Vehicle Damage Warnings CAUTION: ^ Use O-ring seals made of fuel-resistant material. Use of incorrect O-ring seals may result in fuel leakage. ^ Never use silicone grease. Silicone grease may clog fuel injectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 3852 Fuel Rail: Description and Operation NATURAL GAS FUEL SYSTEM Fuel Rail Fuel Rail Components The fuel rail (Figure 78) distributes low pressure fuel from the chassis supply line to each fuel injector. Fuel pressure at the top of each fuel injector is maintained within 1% of the other fuel injectors at all times; this is done with nearly symmetric flow paths. The fuel rail is also designed to have minimal flow restriction by increasing the cross-sectional flow area and reducing the flow path length. The fuel rail contains several other Parts In Assembly (PIA) components that perform crucial functions. These include: Injection pressure sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. - Engine fuel temperature sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. - Low pressure solenoid shut-off valve which isolates the fuel rail from the upstream fuel system when the engine is OFF. This minimizes the amount of fuel available to flow through the fuel injectors when the engine is off or leak from a damaged fuel rail during and after a crash. The valve is controlled by the PCM fuel shut-off valve circuit and contains an inertia switch. The valve is only on for one second after a key-on or whenever CKP signals are being received by the PCM. - schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Fuel Rail Shut-Off Valve Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 3853 Fuel Rail Shut-Off Valve The fuel rail shut-off valve (Figure 86) is a normally closed solenoid actuated valve that opens when (along with all of the tank valves) Pin 80 is grounded by the PCM. The valve isolates the fuel injectors from fuel line pressure when the engine is off. Nominal resistance of the coil is 11 ohms. The fuel rail shut-off valve is wired in parallel with the four tank valves. Fuel Rail Valve Circuit Operation When the key is turned to the ON position, the power relay is turned on. The power relay provides power to the PCM and the control side of the fuel shut off valve relay. The relay provides voltage to the fuel rail valve. If the ignition switch is not turned to the START position, the PCM will shut off the fuel rail valve after one second. The PCM will open the valve (along with the four tank valves) to provide fuel while cranking. The valve will remain open when the engine is running unless the inertia fuel shut-off switch is "tripped." Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 3854 Fuel Rail: Service and Repair Fuel Pipe 1/2 Inch Remover (Green) SPECIAL TOOL(S) REMOVAL 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Relieve the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the air cleaner outlet pipe. 4. Using the special tool, disconnect the fuel line. 5. Disconnect the accelerator cable and, if equipped, the speed control actuator cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 3855 6. Disconnect the fuel pulse damper vacuum hose. 7. Disconnect the fuel injector electrical connectors. 8. Remove the bolts and remove the fuel supply manifold. 9. Inspect the O-ring seals. Discard if damaged. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: ^ Use O-ring seals made of fuel-resistant material. Use of incorrect O-ring seals may result in fuel leakage. ^ Never use silicone grease. Silicone grease may clog fuel injectors. NOTE: Lubricate the O-ring seals with clean Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to aid installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 3856 Fuel Pipe 1/2 Inch Remover (Green) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid > Component Information > Description and Operation Fuel Shut-off Solenoid: Description and Operation NATURAL GAS FUEL SYSTEM Fuel Rail Shut-Off Valve Fuel Rail Shut-Off Valve The fuel rail shut-off valve (Figure 86) is a normally closed solenoid actuated valve that opens when (along with all of the tank valves) Pin 80 is grounded by the PCM. The valve isolates the fuel injectors from fuel line pressure when the engine is off. Nominal resistance of the coil is 11 ohms. The fuel rail shut-off valve is wired in parallel with the four tank valves. Fuel Rail Valve Circuit Operation When the key is turned to the ON position, the power relay is turned on. The power relay provides power to the PCM and the control side of the fuel shut off valve relay. The relay provides voltage to the fuel rail valve. If the ignition switch is not turned to the START position, the PCM will shut off the fuel rail valve after one second. The PCM will open the valve (along with the four tank valves) to provide fuel while cranking. The valve will remain open when the engine is running unless the inertia fuel shut-off switch is "tripped." Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation NATURAL GAS FUEL SYSTEM Fuel Lines and Fittings Fuel Line Assembly A fuel line assembly (Figure 82) consists of flexible hose and/or stainless steel seamless tubing, end fittings and tube nuts. The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced with a stainless steel wire braided covering. The fittings are inserted into the hose ends and crimped into place. The stainless steel tubing contains end fittings which are brazed to the tube. There are high pressure fuel lines that are identified by either 1/4-inch or 3/8-inch outer diameter and a low pressure fuel line identified by a 1/2-inch outer diameter. The low pressure fuel line has a quick-connect at one end for connection to the fuel rail. The other fittings used on the natural gas vehicle to connect fuel components are SAE O-ring face seal tube fittings. There are two end types: an O-ring face seal end and a straight thread end. On tee and elbow fittings, a washer and a positionable nut are provided to aid in orientation of the fitting. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3872 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3873 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3874 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3875 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3876 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3882 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3883 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3884 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3885 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3886 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3887 Fuel Filler Hose: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ THE FUEL TANK MAY BE PRESSURIZED. REMOVE THE FUEL TANK FILLER CAP SLOWLY. IF A HISSING SOUND IS HEARD, WAIT UNTIL THE CONDITION STOPS BEFORE REMOVING THE FUEL TANK FILLER CAP. IF THESE PRECAUTIONS ARE NOT FOLLOWED, FUEL MAY SPRAY AND CAUSE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3888 Fuel Filler Hose: Service and Repair Heavy - Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the left rear wheel. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Remove the gas cap. WARNING: THE FUEL TANK MAY BE PRESSURIZED. REMOVE THE FUEL TANK FILLER CAP SLOWLY. IF A HISSING SOUND IS HEARD, WAIT UNTIL THE CONDITION STOPS BEFORE REMOVING THE FUEL TANK FILLER CAP. IF THESE PRECAUTIONS ARE NOT FOLLOWED, FUEL MAY SPRAY AND CAUSE PERSONAL INJURY. 3. Remove the filler neck retaining screws. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3889 4. Remove the rivets and the fuel tank filler tube shield. 5. Remove the fuel filler tube. 1 Disconnect the hoses. 2 Remove the bolt and the fuel filler tube. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the Heavy-Duty Riveter to install the rivets. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 3890 Heavy - Duty Riveter Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3899 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3900 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3901 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3902 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3903 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3909 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3910 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3911 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3912 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 3913 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Use a suitable jack to support the fuel tank. 3. Disconnect the pin-type retainer from the fuel tank strap and position the parking brake cable aside. 4. Remove the bolts and the fuel tank straps. NOTE: For 4WD vehicles, it will be necessary to disconnect a wiring harness clip from the fuel tank strap. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service Precautions Fuel Tank Unit: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3923 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL VALVE Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The idle air control (IAC) valve assembly (Figure 122) and (Figure 123) controls engine idle speed and provides a dash pot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3924 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 124) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dash pot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3925 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the Idle Air Control (IAC) valve electrical connector. 2. Raise the vehicle. 3. Remove the two bolts and the IAC valve. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Install a new gasket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3929 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System The Inertia Fuel Shutoff (IFS) switch (Figure 73) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System > Page 3932 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System NATURAL GAS FUEL SYSTEM Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Reset Instructions 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. 4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking natural gas. WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE IFS SWITCH. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Page 3933 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Remove the cowl side trim panel. 1 Remove the pin-type retainers. 2 Remove the nut. 3 Remove the cowl side trim panel. 2. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Disconnect the connector. 2 Remove the screws and the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL 1. Disconnect the air cleaner outlet pipe at the mass air flow sensor. ^ Unclip the throttle cable from the outlet pipe. ^ Loosen the screw clamp and disconnect the pipe. 2. Remove the outlet pipe. 1 Disconnect the outlet pipe from the throttle body. 2 Unclip the hose from the outlet pipe. 3 Disconnect the crankcase vent tube and remove the air cleaner outlet pipe. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The air cleaner outlet pipe should be securely sealed to prevent unmetered air from entering the engine. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3940 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3943 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3944 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3945 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3950 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3951 Fuel Pump Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3952 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3956 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay Main Relay (Computer/Fuel System): Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3959 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3960 Main Relay (Computer/Fuel System): Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Micro ISO Relay > Page 3961 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair REMOVAL 1. Remove the left front wheel. 2. Remove the seven pin-type retainers and four screws and position aside the left inner fender splash shield. 3. Remove the bolt and remove the intake air resonator. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the front rubber grommet is seated in the bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3969 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3970 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Remove the four nuts and the MAF sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3974 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3978 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System The Inertia Fuel Shutoff (IFS) switch (Figure 73) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline Fuel System > Page 3981 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System NATURAL GAS FUEL SYSTEM Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Reset Instructions 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. 4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking natural gas. WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE IFS SWITCH. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Page 3982 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Remove the cowl side trim panel. 1 Remove the pin-type retainers. 2 Remove the nut. 3 Remove the cowl side trim panel. 2. Remove the Inertia Fuel Shutoff (IFS) switch. 1 Disconnect the connector. 2 Remove the screws and the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3986 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3987 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3988 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3989 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information Throttle Body: Technician Safety Information 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 3994 Throttle Body: Vehicle Damage Warnings CAUTION: ^ Throttle body bore and plate area have a special coating and should not be cleaned. ^ The throttle body sealing surfaces are soft materials. Use care if cleaning is necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 3995 Throttle Body: Description and Operation THROTTLE BODY SYSTEM OVERVIEW The throttle body system meters air to the engine during idle, part throttle, and Wide Open Throttle (WOT) conditions. The throttle body system consists of an Idle air control (IAC) valve assembly, idle air orifice, single or dual bores with butterfly valve throttle plates and a Throttle Position (TP) sensor. One other source of idle air flow is the Positive Crankcase Ventilation (PCV) system. The combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor on all applications. During idle, the throttle body assembly provides a set amount of air flow to the engine through the idle air passage and PCV valve. The IAC valve assembly provides additional air when commanded by the powertrain control module (PCM) to maintain the proper engine idle speed under varying conditions. The IAC valve assembly mounts directly to the throttle body assembly in most applications, but is remote-mounted to the intake manifold in some applications. Idle speed is controlled by the PCM and cannot be adjusted. NOTE: The traditional idle air adjust procedure as well as throttle return screw are no longer used on OBD II applications. Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle plate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. Some throttle body applications provide an air supply channel upstream of the throttle plate to provide fresh air to the Positive Crankcase Ventilation (PCV) or IAC systems. Other throttle body applications provide individual vacuum taps downstream of the throttle plate for PCV return, Exhaust Gas Recirculation (EGR), Evaporative Emission (EVAP), and miscellaneous control signals. Throttle Body System Hardware The major components of the throttle body assembly include the TP sensor, IAC valve assembly, and throttle body housing assembly. Throttle Position Sensor The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 3996 Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The idle air control (IAC) valve assembly (Figure 122) and (Figure 123) controls engine idle speed and provides a dash pot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 124) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 3997 ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dash pot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Throttle Body Housing The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Features of the Throttle Body Assembly include: 1. Idle air control (IAC) valve assembly mounted directly to the throttle body assembly (some vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps for PCV, EGR, EVAP and miscellaneous control signals (some vehicles only). 5. PCV air return (if applicable). 6. A throttle body-mounted throttle position (TP) sensor. Attention Decal Locations 7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure 121) advising not to clean. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 3998 Throttle Body: Service and Repair REMOVAL 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 BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and should not be cleaned. 1. Remove the air cleaner outlet pipe. 2. Remove the throttle body. 1 Disconnect the accelerator cable and, if equipped, the speed control actuator cable. 2 Disconnect the throttle position sensor electrical connector. 3 Remove the screws and throttle body. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The throttle body sealing surfaces are soft materials. Use care if cleaning is necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Technician Safety Information Throttle Cable/Linkage: Technician Safety Information WARNING: MAKE SURE SURROUNDING COMPONENTS SUCH AS WIRING, HOSES, SOUND INSULATION AND FLOOR CARPETING ARE NOT CONTACTING THE SLIDING INNER CABLE OF THE ACCELERATOR CABLE OR THE ACCELERATOR PEDAL AND SHAFT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Technician Safety Information > Page 4004 Throttle Cable/Linkage: Vehicle Damage Warnings CAUTION: Do not pull the accelerator cable out by the cable housing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Page 4005 Throttle Cable/Linkage: Description and Operation The acceleration control consists of the pedal and shaft assembly, accelerator cable and accelerator cable bracket. WARNING: MAKE SURE SURROUNDING COMPONENTS SUCH AS WIRING, HOSES, SOUND INSULATION AND FLOOR CARPETING ARE NOT CONTACTING THE SLIDING INNER CABLE OF THE ACCELERATOR CABLE OR THE ACCELERATOR PEDAL AND SHAFT. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft. The accelerator pedal and shaft should travel smoothly from the idle to the wide-open throttle positions. Hesitation on return or prevention of return to the idle position must not occur. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service Precautions > Page 4006 Throttle Cable/Linkage: Testing and Inspection For further information regarding the diagnosis of this system, please refer to Accelerator Pedal; Testing and Inspection. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable Throttle Cable/Linkage: Service and Repair Cable REMOVAL 1. Disconnect the accelerator cable from the throttle lever and bracket. 1 Disconnect the accelerator cable from the throttle lever. 2 Disconnect the accelerator cable from the bracket. 2. Disconnect the accelerator cable from the pedal. 3. Remove the accelerator cable. 1 Remove the bracket bolt. 2 Discount the accelerator cable from the air cleaner outlet tube. 3 Remove the accelerator cable from the dash panel. CAUTION: Do not pull the accelerator cable out by the cable housing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: To ease installation, remove the grommet from the throttle lever and install it onto the accelerator cable end. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4009 Throttle Cable/Linkage: Service and Repair Pedal and Shaft REMOVAL 1. Disconnect the accelerator cable from the throttle lever and bracket. 2. Remove the accelerator pedal and shaft assembly. 1 Disconnect the accelerator cable. 2 Remove the bolts. INSTALLATION 1. To install, reverse the removal procedure. NOTE: To ease installation, remove the grommet from the throttle lever and install it onto the accelerator cable end. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4013 Throttle Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4014 Throttle Position Sensor: Service Precautions CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4015 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4016 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the Throttle Position (TP) sensor electrical connector. 2. Remove the two screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to hand start the TP sensor screws. These are self-threading screws. Failure to hand start them can cause damage to the throttle body. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications 4-Cyl Firing Order: 1 3 4 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4021 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4029 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4030 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4031 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4035 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4036 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4037 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. ^ Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 4041 Ignition Cable: Service and Repair REMOVAL 1. Grasp the spark plug boot firmly and with a twisting-pulling motion, disconnect the ignition wires from the spark plugs. CAUTION: Do not pull on the ignition wire directly, as the wire may separate from the connector inside the spark plug boot. 2. Disconnect the ignition wires from the ignition coil and remove the wires. INSTALLATION 1. Connect the ignition wires to the correct ignition coil terminals. CAUTION: Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plug or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. NOTE: ^ Whenever an ignition wire is reinstalled or a new one is installed, apply Silicone Brake Caliper Grease and Dielectric compound to the interior surface of the ignition wire boot. ^ Before installing the ignition wires, inspect the ignition wires for any visible damage; install new ignition wires if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 4042 2. Connect the ignition wires to the correct spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4047 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4048 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4049 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4050 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4051 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4052 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4055 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4056 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4057 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4058 Ignition Coil: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4059 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4060 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug (CoP) #1 > Page 4061 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4062 Ignition Coil: Service Precautions CAUTION: Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plugs or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4063 Ignition Coil: Description and Operation COIL PACK Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4064 Four-Tower Coil Packs Series 5 Four Tower Coil Pack Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4065 Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six tower models. Two adjacent coil towers share a common coil and are called a matched pair. For six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4 (Figure 58) and (Figure 59). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 60) and (Figure 61). When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Coil Bracket Ignition Coil: Service and Repair Coil Bracket REMOVAL 1. Remove the ignition coil. 2. Remove the bracket. 1 Remove the Exhaust Gas Recirculation (EGR) tube bracket bolt. 2 Remove the three bolts and remove the ignition coil bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Coil Bracket > Page 4068 Ignition Coil: Service and Repair Coil Pack REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the ignition wires. 3. Disconnect the ignition coil electrical connectors. 4. Remove the bolts and remove the ignition coil. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Correct installation of the ignition wires is critical to engine operation. If one spark plug wire is not correctly installed at either the spark plugs or the ignition coil, both spark plugs connected to the ignition coil may not fire under load. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4072 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4073 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 4074 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4078 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4079 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4084 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4085 Ignition Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 4086 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4091 Camshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4092 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4093 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4097 Crankshaft Position Sensor: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4098 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4099 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the exhaust manifold. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL 1. Disconnect the battery ground cable. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4107 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4108 Knock Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Disconnect the KS electrical connector and remove the connector from the mounting bracket. NOTE: The Knock Sensor (KS) is located on the RH side of the cylinder block. 3. Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap Spark Plug Gap 0.048-0.052 inch (1.22-1.32 mm) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4112 Spark Plug: Service Precautions CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4113 Spark Plug: Application and ID Spark plug cylinders 1 and 3................................................................................................................ ....................................................................AZFS-32F Spark plug cylinders 2 and 4........................... .......................................................................................................................................................AZF S-32FE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4114 Spark Plug: Service and Repair REMOVAL CAUTION: Do not pull on the ignition wire directly, as it may separate from the connector inside the boot. 1. Grasp the spark plug boot firmly and with a twisting-pulling motion remove the spark plug wires from the spark plug. 2. Remove the spark plugs. NOTE: ^ If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs can be used in any cylinder. ^ Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. 3. Inspect the spark plugs. INSTALLATION 1. Adjust the plug gap as necessary. NOTE: Clean the spark plugs with a wire brush or a professional spark plug cleaner (follow the manufacture's instructions). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4115 2. Install the spark plugs. NOTE: Apply Anti-Seize Lubricant to the lower three threads of the spark plugs. Do not allow lubricant to contaminate the spark plug electrodes or insulator tips. 3. Connect the spark plug wires to the spark plugs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair SELECTOR LEVER INDICATOR BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the selector lever indicator bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4136 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4137 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4143 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4144 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4145 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4146 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4147 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4148 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine Shaft Speed (TSS) sensor bolt .................................................................................................................................................... 13 Nm (10 ft. lbs.) Output Shaft Speed (OSS) sensor bolt ..................................................................................................................................................... 13 Nm (10 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4154 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Connector Output Shaft Speed (OSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4157 Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor Connector Turbine Shaft Speed (TSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4158 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4159 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Remove the Output Shaft Speed (OSS) sensor. ^ Disconnect the OSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the OSS bore. 5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4162 1. NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Install the OSS sensor. ^ Connect the OSS sensor electrical connector. 2. Install the splash shield. 3. Install the LH front wheel. 4. Lower vehicle. 5. Check the transmission fluid level, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 6. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4163 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Place a drain pan beneath the Turbine Shaft Speed (TSS) sensor. 5. Remove the TSS sensor. ^ Disconnect the TSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the TSS sensor bore. 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4164 1. NOTE: Apply a light coat of petroleum jelly to the O-ring seal before installation. Install the TSS sensor. ^ Connect the TSS electrical connector (white connector). 2. Remove the drain pan. 3. Install the splash shield. 4. Install the LH front wheel. 5. Lower the vehicle. 6. Check the transmission fluid level, add fluid as necessary using clean automatic transmission fluid. 7. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) bolt ............................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4169 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the bolt and the VSS. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4174 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4175 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications Accumulator: Specifications Accumulator body transfer plate bolts ........................................................................................................................................................ 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair Band Apply Servo: Service and Repair Overdrive Servo Special Tool(s) Removal 1. NOTE: Servicing the intermediate/overdrive servo in the vehicle is only recommended in the event of a leak. If servicing is required due to a servo condition, it is necessary to remove and disassemble the transaxle to inspect the intermediate/overdrive band assembly and direct clutch for damage. Raise the vehicle on a hoist. 2. WARNING: The servo is under pressure. Servo and servo cover are under high spring force. Use caution when removing servo cover. Failure to follow these instructions may result in personal injury. Assemble the special tool. 3. Remove the splash shield. 4. Remove the transmission cooler line bracket and bolt, and position the bracket out of the way. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4197 5. CAUTION: Do not use a screwdriver to remove the retaining ring or damage to the case may occur. Use only snap ring pliers to remove the retaining ring. Using the special tool, remove the servo retaining ring. 1 Install the special tool. 2 Compress the servo assembly by tightening the bolt. 3 Remove the retaining ring. 6. Remove the special tool. 7. Remove the servo cover assembly. 8. Remove the intermediate and overdrive servo piston and return spring. 9. Wipe the servo piston and the servo cover cap with a lint-free cloth. 10. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and the servo cover cap with cleaning solvent or damage to the sealing surface may result. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston is attached to the servo rod. 11. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston. 12. Inspect the servo retainer spring for cracks, breaks or deformation. Installation 1. WARNING: Servo return spring force is very high. Failure to follow these instructions may result in personal injury. Assemble the special tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4198 2. Install the special tool. 3. CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring. NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed. Tighten the special tool bolt. ^ Install the servo cover retaining ring. 4. If the case is stamped "WG", install a wide-groove snap ring, or the servo will be damaged. 5. Loosen the special tool bolt. ^ When the spring tension is released, remove the special tool. 6. Install the transmission fluid cooler line. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 4199 7. Install the splash shield. 8. Lower the vehicle. 9. Start the vehicle. Place transmission range selector lever in each gear and allow to engage. Check for leaks. 10. Check transmission fluid. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications Differential Fluid - A/T: Specifications Ford Part Name - MERCON(R) V Automatic Transmission Fluid Ford Part Number - XT-5-QM Ford Specification - MERCON(R) V Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drain Plug, A/T > Component Information > Specifications Drain Plug: Specifications Drain plug ............................................................................................................................................ ..................................................... 27 Nm (20 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4211 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4212 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ............................................................... 10 Qt (9.5L) Note: Approximately Dry Fill Capacity Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4215 Fluid - A/T: Fluid Type Specifications Ford Part Name - MERCON(R) V Automatic Transmission Fluid Ford Part Number - XT-5-QM Ford Specification - MERCON(R) V Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Material Removal 1. Raise and support the vehicle. 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. Installation 1. 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 D8AZ-19554-A or XW7Z-19554-AA or equivalent meeting Ford specification WSK-M2G350-A2. 2. Lower the vehicle 3. Add 3.7 liters (3.9 quarts) of MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 4. Start the engine and run through all gears for a total of five minutes at idle. Turn off the engine. 5. Repeat the previous steps to help flush fluid from the torque converter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4218 Fluid - A/T: Service and Repair Check Fluid Level and Condition Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and the outside temperature is above 10°C (50°F). NOTE: Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (20 miles). If your vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather, or while pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. Under normal circumstances, there is no need to check the fluid level of the transaxle, since the vehicle does not use up transmission fluid. However, if the transaxle is not working correctly, for instance, the transaxle may slip or shift slowly, or there may be some sign of fluid leakage, the fluid level should be checked. Fluid Level Check 1. Drive the vehicle 30 km (20 miles) or until the vehicle reaches normal operating temperatures. 2. Park the vehicle on a level surface and engage the parking brake. 3. With your foot on the brake, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 4. Place the range selector in P (park) and leave the engine running. 5. Remove the fluid level indicator and wipe it clean with a clean cloth. 6. Install the fluid level indicator, making sure that it is fully seated in the filler tube. 7. Remove the fluid level indicator. The fluid should be in the designated areas for normal and room temperature. Low Fluid Level Do not drive the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator and the outside temperature is above 10°C (50°F). High Fluid Level Fluid levels above the safe range can result in transmission failure. An overfill condition of transmission fluid can cause shift or engagement concerns, or possible damage. High fluid levels can cause an overheating condition. See the previous note. Adding Fluid CAUTION: Use of a non-approved automatic transmission fluid can cause internal transmission component damage. An overfill condition of transmission fluid can cause shift or engagement concerns, or possible damage. Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the fluid level indicator. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4219 If necessary, add fluid in 250 ml (1/2 pint) increments through the filler tube until the level is correct. If an overfill condition occurs, excess fluid should be removed by a qualified technician. Fluid Condition Check NOTE: Evidence of fluid contamination, breakdown, or incorrect fluid can cause poor shift quality. If the transmission fluid condition is suspect, drain the transaxle and replace the fluid with MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. ^ Make the normal fluid level check as described in, Fluid Level Check. ^ Observe the color and odor of the fluid. It should be red, not brown or black. Odor can indicate an overheating condition or clutch disc or band failure. ^ Use a clean, lint-free cloth and wipe the fluid level indicator. Examine the stain for evidence of solid particles and signs of antifreeze (gum or varnish on the fluid level indicator). If particles are present in the fluid or there is evidence of contamination, the transaxle drain plug should be removed and a sample of the fluid filtered through a paper filter and examined. If transaxle failure is confirmed by further evidence of coolant or excessive particles in the fluid, the transaxle must be completely cleaned and repaired. This includes cleaning and flushing the torque converter and transaxle cooling system. During disassembly and assembly all overhaul checks and adjustments of clearances and end play must be made. After repairing the transaxle, all diagnostic tests and adjustments listed in the diagnosis must be completed to make sure that the problem has been eliminated. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Locations Fluid Filter - A/T: Locations Part 1 Of 7 Transmission Fluid Filter Location Filter is located at exploded view position number 8 internal. See Transmission Disassembly/Assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Locations > Page 4223 Special Tool Seal Removal Transmission Filter Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Cooler line fitting .................................................................................................................................. .................................................... 40 Nm (30 ft. lbs.) Cooler inlet line ................................................. ....................................................................................................................................... 23 Nm (17 ft. lbs.) Transaxle cooler lines .................................................................................................................. ............................................................. 23 Nm (17 ft. lbs.) Auxiliary cooler bolts ................................ ............................................................................................................................................ 10 Nm (89 inch lbs.) Cooler tube bracket bolt ....................................................................................................... .................................................................... 25 Nm (18 ft. lbs.) Cooler tube fittings ............................ ....................................................................................................................................................... 25 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Pump assembly bolts .......................................................................................................................... ...................................................... 13 Nm (10 ft. lbs.) Pump support bolts ......................................... .......................................................................................................................................... 13 Nm (10 ft. lbs.) Drive gear clearance ...................................................................................................................................................... 0.05 - 0.08 mm (0.002 - 0.003 inch) Drive shaft rotational torque ............................................................... ....................................................................................................... 0.3 mm (2.6 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair SELECTOR LEVER INDICATOR BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the selector lever indicator bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Specifications Parking Pawl: Specifications Parking pawl shaft retainer bolt ........................................................................................................... .................................................... 8 Nm (71 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4244 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4245 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals - LH Seals and Gaskets: Service and Repair Differential Fluid Seals - LH Differential Fluid Seals - LH Special Tool(s) Removal 1. Raise and support the vehicle. 2. NOTE: Place a suitable drain pan under the vehicle. Remove the transaxle drain plug and drain the fluid. 3. Remove the LH halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals - LH > Page 4250 4. Using the special tools, remove and discard the LH differential seal Installation 1. Using the special tool, install the LH differential seal. 2. Install the LH halfshaft. 3. Remove the drain pan and lower the vehicle. 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. 5. Add automatic transmission fluid. 6. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary. 7. Allow the transmission fluid to reach operating temperature and fill as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals - LH > Page 4251 Seals and Gaskets: Service and Repair Differential Fluid Seals - RH Differential Fluid Seals - RH Special Tool(s) Removal 1. Raise and support the vehicle. 2. NOTE: Determine the source of the fluid leak. If the leak is from the transaxle, continue with this procedure. If it is determined that the fluid leak is coming from the Power Take-Off (PTO) unit, remove the PTO. 3. NOTE: Place a suitable drain pan under the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals - LH > Page 4252 Remove the transaxle drain plug and drain the fluid. 4. Remove the RH halfshaft. 5. If equipped remove the PTO. 6. If the vehicle is equipped with a PTO, use the special tools to remove the RH differential seal. 7. If the vehicle is not equipped with a PTO, use the special tools to remove the RH differential seal. Installation 1. If the vehicle is equipped with a PTO, use the special tools to install the RH differential seal. 2. If the vehicle is not equipped with a PTO, use the special tools to install the RH differential seal. 3. If equipped install the PTO. 4. Install the RH halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Differential Fluid Seals - LH > Page 4253 5. Install the transaxle drain plug. ^ After the fluid has been drained, clean the drain plug threads and apply a small amount of pipe sealant. 6. Remove the drain pan and lower the vehicle. 7. Add automatic transmission fluid. 8. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary. 9. Allow the transmission fluid to reach operating temperature and fill as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4258 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4259 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4260 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4261 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4262 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4263 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine Shaft Speed (TSS) sensor bolt .................................................................................................................................................... 13 Nm (10 ft. lbs.) Output Shaft Speed (OSS) sensor bolt ..................................................................................................................................................... 13 Nm (10 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4269 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Connector Output Shaft Speed (OSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4272 Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor Connector Turbine Shaft Speed (TSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4273 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4274 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Remove the Output Shaft Speed (OSS) sensor. ^ Disconnect the OSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the OSS bore. 5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4277 1. NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Install the OSS sensor. ^ Connect the OSS sensor electrical connector. 2. Install the splash shield. 3. Install the LH front wheel. 4. Lower vehicle. 5. Check the transmission fluid level, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 6. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4278 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Place a drain pan beneath the Turbine Shaft Speed (TSS) sensor. 5. Remove the TSS sensor. ^ Disconnect the TSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the TSS sensor bore. 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4279 1. NOTE: Apply a light coat of petroleum jelly to the O-ring seal before installation. Install the TSS sensor. ^ Connect the TSS electrical connector (white connector). 2. Remove the drain pan. 3. Install the splash shield. 4. Install the LH front wheel. 5. Lower the vehicle. 6. Check the transmission fluid level, add fluid as necessary using clean automatic transmission fluid. 7. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4284 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4285 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications Nuts - selector lever ............................................................................................................................. .................................................... 9 Nm (80 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 4292 Shifter A/T: Service and Repair Selector Lever Removal and Installation NOTE: LH drive is shown, RH drive is similar. 1. Remove the clockspring. 2. Remove the multifunction switch. 3. Remove the windshield wiper/washer switch. 4. Disconnect the gearshift cable. 5. Disconnect the electrical connector. 6. Disconnect the wiring harness from the gear shifter assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 4293 7. Remove the bolts and the gearshift lever assembly. 8. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Automatic Transmission/Transaxle Shift cable bracket bolts ...................................................................................................................... ................................................. 23 Nm (17 ft. lbs.) External Controls Gearshift cable bracket bolts ............................................................................................................... ................................................. 23 Nm (17 ft. lbs.) Gearshift cable nuts ............................................. .............................................................................................................................. 10 Nm (89 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4298 Shift Cable: Adjustments Selector Lever Cable Adjustment Special Tool(s) 1. Remove the upper steering column shroud. 2. Remove the lower steering column shroud. 1 Remove the screws. 2 Remove the lower steering column shroud. 3. Position a 0.6 mm (0.023 inch) feeler gauge between the gearshift lever selector and the gearshift lever detent. 4. Place the gearshift lever in the DRIVE position and hang a 1.4 kg (3 lb) weight from the gearshift lever. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4299 5. Loosen the gearshift cable adjuster to adjust the cable then tighten. 6. Remove the weight from the gearshift lever. 7. Place the gearshift lever in the PARK position and remove the feeler gauge. 8. Install the lower steering column shroud. 1 Position the lower steering column shroud. 2 Install the screws. 9. Install the upper steering column shroud. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4300 Shift Cable: Service and Repair Selector Lever Cable Special Tool(s) Removal NOTE: LH drive shown; RH drive similar. 1. Remove the upper steering column shroud. 2. Remove the lower steering column shroud. 1 Remove the screws. 2 Remove the lower steering column shroud. 3. Disconnect the gearshift cable from the steering column bracket. 1 Disconnect the gearshift cable from the gearshift lever. 2 Disconnect the gearshift cable from the steering column bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4301 4. Remove the gearshift cable nuts. 5. Detach the gearshift cable from the transaxle shifter lever. 6. Disconnect the gearshift cable from the bracket by depressing the locking tabs at the bracket. 7. Remove the gearshift cable. Installation NOTE: LH drive shown; RH drive similar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4302 1. Install the gearshift cable. 2. Install the gearshift cable in the bracket. 3. Connect the gearshift cable to the transaxle shifter lever. 4. Install the gearshift cable nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4303 5. Connect the gearshift cable to the gearshift lever. 1 Attach the gearshift cable to the steering column bracket. 2 Connect the gearshift cable to the gearshift lever. 6. Position a 0.6 mm (0.023 inch) feeler gauge between the gearshift lever selector and the gearshift lever detent. 7. Place the gearshift lever in the DRIVE position and hang a 1.4 kg (3 lb) weight from the gearshift lever. 8. Loosen the gearshift cable adjuster to adjust the cable then tighten. 9. Install the lower steering column shroud. 1 Position the lower steering column shroud. 2 Install the screws. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4304 10. Install the upper steering column shroud. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Torque converter nuts ......................................................................................................................... ...................................................... 36 Nm (27 ft. lbs.) Torque converter pump rotational torque .......................................................................................................................................... 0.3 Nm (2.65 inch lbs.) Torque converter housing lower front mount bracket ............................................................................................................................... 90 Nm (66 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4308 Torque Converter: Description and Operation Torque Converter The torque converter is a four element assembly. The torque converter contains an impeller, a turbine, a reactor, and a Torque Converter Clutch (TCC) for increased fuel economy. It couples the engine to the turbine shaft assembly, provides torque multiplication and absorbs engine shock of gear shifting. Impeller and Cover The impeller and cover assembly drives the impeller blades and pump assembly. The impeller is primarily responsible for driving the turbine with hydraulic fluid by means of centrifugal force. The cover provides a mating surface for the torque converter clutch piston plate and damper assembly. Turbine The turbine is driven by centrifugal fluid force from the impeller. The turbine transmits input torque to the drive chain and driven sprocket through the turbine shaft. Reactor The reactor redirects fluid flow from the turbine back to the impeller so that fluid rotates in the same direction as the impeller. This action also assists in torque multiplication. Torque Converter Clutch (TCC) The Torque Converter Clutch (TCC) provides a mechanical link or direct drive between the engine crankshaft and turbine shaft when applied. The application of the torque converter clutch is controlled by the Powertrain Control Module (PCM). Under certain conditions, the PCM sends the appropriate signal to the TCC solenoid which allows fluid pressure within the torque converter to force the TCC piston plate and damper assembly against the cover creating a mechanical link between the engine and transaxle. Turbine Shaft The turbine shaft connects the torque converter stator with the forward/coast/direct clutch cylinder. When applied, the forward/coast/direct clutch cylinder transmits input torque to the reverse/overdrive ring gear assembly, which also acts as the drive sprocket. This allows input torque to be Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4309 transmitted from the torque converter to the drive chain and driven sprocket. Geartrain The geartrain includes the planetary gearsets, apply components, and final drive gearset and differential. Planetary Gearsets The automatic transaxle has two planetary gearsets to provide operation in reverse and four forward speeds. The gearsets are comprised of the following components: ^ Low/intermediate sun gear assembly. ^ Low/intermediate carrier assembly. ^ Low/intermediate ring gear assembly. ^ Reverse/overdrive sun gear and shell assembly. ^ Reverse/overdrive carrier assembly. ^ Reverse/overdrive ring gear assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4310 Drive Chain and Sprockets A chain drive transfers torque from the torque converter turbine to the planetary gearsets. The chain drive is composed of the following components: ^ Reverse/overdrive ring gear assembly which 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. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4311 The final drive consists of a planetary gearset that transfers and multiplies torque from the planetary gearsets to the differential. The final drive consists of the following components: ^ Final drive sun gear: is chain driven by the reverse/overdrive ring gear assembly and transfers torque to the final drive carrier. ^ Final drive carrier: the final drive carrier acts as the driven member and is part of the differential case. ^ Final drive ring gear: is held by the converter housing and is always the held member of the final drive planetary gearset. The differential assembly drives the differential pinion gears and the differential side gears which in turn drive the front wheel driveshaft and joints, and provides differential action if driving wheels are turning at different speeds. The differential assembly consists of the following components: ^ Differential case (part of the final drive carrier). ^ Two pinion gears supported by a pinion shaft. ^ Two side gears supported by the differential case and halfshafts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T CD4E - Cold Weather Transmission Failure Transmission Cooler: Technical Service Bulletins A/T CD4E - Cold Weather Transmission Failure TSB 09-25-4 12/28/09 CD4E TRANSMISSION FAILURE - REPLACE OR INSTALL TRANSMISSION FLUID COOLER COLD WEATHER BYPASS KIT FORD: 2001-2008 Escape MERCURY: 2001-2008 Mariner This article supersedes TSB 4-14-1 to update the model year coverage, Part List and Service Procedure. ISSUE Some 2001-2008 Escape and Mariner vehicles equipped with a CD4E transmission may experience a transmission failure due to inadequate lube flow during warm up in cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow the Workshop Manual, Section 307-01 service procedure to repair the transmission. When overhauling or replacing a CD4E transmission, always install a new cold weather transmission fluid bypass kit, even if not previously equipped. Do not flush or back flush existing transmission cooler bypass valve system or cooler tube system. Follow instruction sheets included in the new Cold Weather Transmission Fluid Cooler Bypass Kit. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT092504 Claim Diagnosis And Labor Actual Performed As Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 7K177 55 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T CD4E - Cold Weather Transmission Failure > Page 4316 Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T CD4E - Cold Weather Transmission Failure > Page 4317 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T CD4E - Cold Weather Transmission Failure > Page 4318 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4319 Transmission Cooler: Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4320 Transmission Cooler: Description and Operation Transaxle Cooling All vehicles with automatic transmissions are equipped with a transmission fluid cooler integral to the radiator which cannot be repaired separately. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Inspection and Verification 1. Verify the customer's concern by operating the vehicle to duplicate the condition. 2. If the inspection reveals obvious concern(s) that can be readily identified, repair as necessary. 3. Install new components if a fluid leak is found in any of the transaxle cooling components. 4. If the concern(s) remains after the inspection, determine the symptom(s) and See: Symptom Related Diagnostic Procedures. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4323 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4324 Transmission Cooler: Component Tests and General Diagnostics Transmission Fluid Cooler - Backflushing and Cleaning Special Tool(s) CAUTION: Test the Torque Converter Cleaner to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 1. NOTE: Rubber hoses must be attached to the ends of this fluid cooler tubes to connect them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to the fluid cooler inlet tube. 2 Connect the return line to the fluid cooler outlet tube. 3 Place the outlet end of the return line in the solvent tank reservoir. 2. NOTE: Cycling the solvent pump on and off will help dislodge contaminants in the cooler system. Switch the solvent pumps on. Allow the solvent to circulate a minimum of five minutes. 3. Switch the solvent pump off. 4. Disconnect the cleaner pressure line at the fluid cooler tube. 5. Using compressed air, blow through the fluid cooler inlet tube until all solvent is removed. 6. Remove the rubber hoses from the fluid cooler tubes. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler Transmission Cooler: Service and Repair Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Removal and Installation 1. Remove the front bumper cover. 2. Disconnect the cooler tubes. 3. Remove the bolts and the auxiliary transmission fluid cooler. 4. To install, reverse the removal procedure. ^ Fill the transaxle to the specified level. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4327 Transmission Cooler: Service and Repair Transmission Fluid Cooler Tubes Transmission Fluid Cooler Tubes Removal and Installation 1. Remove the front bumper cover. 2. Disconnect the cooler tubes. 3. Disconnect the front cooler tube. 4. Disconnect and remove the front cooler tube. 5. Disconnect the rear cooler tube. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 4328 6. Remove the rear transmission cooler tube bracket bolt and the cooler tube. 7. Lower the vehicle. 8. Disconnect and remove the integral to auxiliary cooler tube. 9. To install, reverse the removal procedure. ^ Fill the transaxle to the specified level. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front Transmission Mount: Service and Repair Transaxle Support Insulator - Lower, Front Transaxle Support Insulator - Lower, Front Removal 1. Raise and support the vehicle. 2. Remove the splash shield. 3. Remove the cross brace. 4. Remove the lower vibration dampener. 5. Remove the cross brace. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4333 6. Remove the top and bottom mount cups. 7. Remove the rubber mount. Installation 1. Install a new rubber mount. 2. Install the top and bottom mount cups. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4334 3. Install the cross brace. 4. Install the lower vibration dampener. 5. Install the cross brace. 6. Install the splash shield. 7. Lower the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4335 Transmission Mount: Service and Repair Transaxle Support Insulator - Lower, Rear Transaxle Support Insulator - Lower, Rear, 2.0L 4V Removal 1. Disconnect the battery cables. 2. Remove the battery tray. 3. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 4. Remove the intake tube and air cleaner cover. 5. Remove the air cleaner assembly. 6. Remove the bolts from the rack. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4336 7. Remove the bolts and nuts from the mount, and remove the mount. Installation 1. NOTE: Prior to tightening the mount nuts install the mount bolt for correct alignment. Install a new mount and bolts. 1 Install the mount. 2 Loosely install the bolt for correct alignment. 3 Install the nuts and bolt. 2. Install the bolts to the rack. 3. Install the air cleaner assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4337 4. Install the intake tube and air cleaner cover. 5. Connect the breather tube and Mass Air Flow (MAF) sensor. 6. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 7. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Connect the battery cables. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4338 Transmission Mount: Service and Repair Transaxle Support Insulator - LH Transaxle Support Insulator - LH Special Tool(s) Removal 1. Disconnect the breather tube and Mass Air Flow (MAF) sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4339 2. Remove the intake tube and air cleaner cover. 3. Remove the air cleaner assembly. 4. Install the special tools. 5. Install the special tools. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4340 6. Remove the upper transaxle mount bolt. 7. Remove the upper transaxle insulator. 8. Remove the top and bottom mount cups. Installation 1. Install the top and bottom mount cups. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4341 2. Install the upper transaxle insulator. 3. Install the upper transaxle bolt. 4. Remove the special tool. 5. Remove the special tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transaxle Support Insulator - Lower, Front > Page 4342 6. Install the air cleaner assembly. 7. Install the intake tube and air cleaner cover. 8. Connect the breather tube and Mass Air Flow (MAF) sensor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4346 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4347 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4348 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4349 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4350 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4351 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine Shaft Speed (TSS) sensor bolt .................................................................................................................................................... 13 Nm (10 ft. lbs.) Output Shaft Speed (OSS) sensor bolt ..................................................................................................................................................... 13 Nm (10 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4357 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Connector Output Shaft Speed (OSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4360 Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor Connector Turbine Shaft Speed (TSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4361 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4362 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Remove the Output Shaft Speed (OSS) sensor. ^ Disconnect the OSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the OSS bore. 5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4365 1. NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Install the OSS sensor. ^ Connect the OSS sensor electrical connector. 2. Install the splash shield. 3. Install the LH front wheel. 4. Lower vehicle. 5. Check the transmission fluid level, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 6. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4366 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Place a drain pan beneath the Turbine Shaft Speed (TSS) sensor. 5. Remove the TSS sensor. ^ Disconnect the TSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the TSS sensor bore. 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4367 1. NOTE: Apply a light coat of petroleum jelly to the O-ring seal before installation. Install the TSS sensor. ^ Connect the TSS electrical connector (white connector). 2. Remove the drain pan. 3. Install the splash shield. 4. Install the LH front wheel. 5. Lower the vehicle. 6. Check the transmission fluid level, add fluid as necessary using clean automatic transmission fluid. 7. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Control valve body-to-transfer plate bolts .................................................................................................................................................. 12 Nm (9 ft. lbs.) Manual control lever bolt ..................................................................................................... .................................................................... 27 Nm (20 ft. lbs.) Solenoid valve body bolts ................. .................................................................................................................................................... 10 Nm (89 inch lbs.) Main control valve body cover bolts ........................................................................................................................................................ 16 Nm (12 ft. lbs.) Main control cover bolts .............................................................................................. ............................................................................. 20 Nm (15 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4371 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4372 Valve Body: Service and Repair Main Control Valve Body Special Tool(s) Removal 1. Disconnect the battery cables. 2. Remove the battery and tray. 3. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 4. Remove the intake tube and air cleaner cover. 5. Disconnect the transaxle wiring harness electrical connector, and TR sensor connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4373 6. Disconnect the shift cable. 7. Remove the shift cable and bracket, and position out of the way. 8. Remove the vent tube hose. 9. Raise and support the vehicle. 10. Remove the LH front wheel. 11. Remove the splash shield. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4374 12. NOTE: Remove the bolts in the indicated sequence. Remove the main control cover. 13. Remove the main control cover gasket. 14. NOTE: Remove the bolts in the indicated sequence. Remove the main control valve body bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4375 15. NOTE: Do not damage the manual valve. Lift the main control valve body while disconnecting the manual valve link. 16. Depress the retaining tabs and push the solenoid valve body electrical connector down through the transaxle case. 17. Make sure the manual valve control lever does not fall out of the main control valve body while removing from the vehicle. Installation 1. Install the manual control valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4376 2. NOTE: Inspect the solenoid valve body harness connector O-ring seal for damage. Install a new O-ring seal, if damaged, before installing the connector into the case. Push the solenoid valve body harness connector into the case. 3. Connect the manual valve link to the main control valve body. 4. Install the main control valve body and tighten the bolts in sequence as indicated. 5. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4377 6. Install the manual control lever. 7. Install and 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 8. Install a new gasket on the main control cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4378 9. Install the main control cover, and tighten the bolts in sequence as shown. 10. Install the splash shield. 11. Install the LH front wheel. 12. Lower the vehicle. 13. Install the shift cable and bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4379 14. Connect the shift cable. 15. NOTE: Before installing the vent tube hose, clean out any obstructions in the hose using low air pressure. Install the vent tube hose to the fitting on the main control cover. 16. Connect the transaxle harness connector, and the TR sensor connector. 17. Install the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4380 18. Connect the breather tube and Mass Air Flow (MAF) sensor. 19. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery tray and battery. 20. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Connect the battery cables. 21. Check the transmission fluid, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 22. Start the engine and move the transaxle range selector lever through all gear positions. Refill as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications Clutch disc inner diameter ................................................................................................................... ................................................... 150 mm (5.91 inch) Clutch disc outer diameter ............................... ....................................................................................................................................... 225 mm (8.86 inch) Clutch disc Minimum thickness .............................................................................................................................. .............................................. 0.3 mm (0.012 inch) Maximum runout .................................................. ........................................................................................................................... 0.7 mm (0.0276 inch) Set load ............................................................................................................................................... ................................................. 4.900 N (1.102 lb.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4385 Clutch Disc: Service and Repair Clutch Disc and Pressure Plate Special Tool(s) Removal WARNING: Clutches and brakes contain asbestos fibers. Avoid breathing dust. Breathing asbestos dust may cause asbestosis and cancer. Failure to follow these instructions may result in personal injury. Breathing asbestos dust is hazardous to your health. Failure to follow these instructions may result in personal injury. Dust and dirt present on wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing. Failure to follow these instructions may result in personal injury. Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum 164-R3600. Dust and dirt from vacuum should be disposed of in a manner that prevents dust exposure such as sealed bags. The bag must be labeled as per OSHA instructions and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. Grinding or sanding on brake linings, pads, rotors, drums or clutch facings should be done only while using correctly exhaust-ventilated equipment. Failure to follow these instructions may result in personal injury. OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with carrying out brake or clutch service should be present in the area. Failure to follow these instructions may result in personal injury. 1. Remove the transaxle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4386 2. Using the special tool lock the flywheel to the engine 3. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury. CAUTION: Loosen bolts evenly to prevent pressure plate damage. Remove the bolts, clutch pressure plate, and clutch disc 4. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Using a suitable commercial alcohol base solvent, clean the clutch pressure plate 5. Inspect the clutch pressure plate surface for burn marks, scores flatness or ridges 6. Inspect the clutch pressure plate diaphragm fingers for wear. Install a new clutch pressure plate as necessary 7. Measure the depth to the rivet heads. Install a new clutch disc if any rivet head measurement is not within specifications. 8. CAUTION: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation. NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface. Install a new clutch disc if any of the following conditions are present. Inspect the clutch disc for: ^ oil or grease saturation ^ worn or loose facings ^ warpage or loose rivets at the hub ^ loose or broken torsion dampening springs Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4387 ^ wear or rust on splines 9. Using the special tool, check clutch disc runout. Install a new clutch disc if not within specifications. 10. NOTE: Install a new clutch release fork if any of the following conditions are present. Inspect the clutch release fork for: ^ cracks ^ distortion ^ excessive wear on the release bearing contact surface Installation 1. Using the special tool, position the clutch disc on the flywheel. 2. Position the clutch pressure plate on the flywheel, install the pressure plate bolts and tighten them in sequence to specification. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 4388 3. Remove the special tool. 4. Remove the special tool. 5. Install the transaxle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Clutch Fluid Clutch Fluid Fill to the line on the reservoir. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 4394 Clutch Fluid: Fluid Type Specifications Clutch Fluid Clutch Fluid High Performance DOT 3 Motor Vehicle Brake Fluid. The hydraulic clutch system uses the same reservoir as the hydraulic brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 06-9-4 > May > 06 > M/T - Clutch Master Cylinder Squeaking Noise Clutch Master Cylinder: Customer Interest M/T - Clutch Master Cylinder Squeaking Noise TSB 06-9-4 05/15/06 SQUEAKING NOISE FROM CLUTCH MASTER CYLINDER FORD: 2001-2004 Escape ISSUE Some 2001-2004 Escape vehicles may exhibit a squeaking noise from the clutch master cylinder as the clutch pedal is depressed or released. This noise is typically only present in ambient temperatures of 70° F (21° C) or higher. This condition may be caused by the design of the master cylinder seal. ACTION Install an updated master cylinder containing a seal with an improved design. Replace the master cylinder following the procedure in Workshop Manual, Section 308-02. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060904A 2001-2004 Escape 0.8 hr. 4X2/4X4: Replace Clutch Master Cylinder (Do Not Use With 7543A) DEALER CODING CONDITION BASIC PART NO. CODE 7A543 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 06-9-4 > May > 06 > M/T - Clutch Master Cylinder Squeaking Noise Clutch Master Cylinder: All Technical Service Bulletins M/T - Clutch Master Cylinder Squeaking Noise TSB 06-9-4 05/15/06 SQUEAKING NOISE FROM CLUTCH MASTER CYLINDER FORD: 2001-2004 Escape ISSUE Some 2001-2004 Escape vehicles may exhibit a squeaking noise from the clutch master cylinder as the clutch pedal is depressed or released. This noise is typically only present in ambient temperatures of 70° F (21° C) or higher. This condition may be caused by the design of the master cylinder seal. ACTION Install an updated master cylinder containing a seal with an improved design. Replace the master cylinder following the procedure in Workshop Manual, Section 308-02. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060904A 2001-2004 Escape 0.8 hr. 4X2/4X4: Replace Clutch Master Cylinder (Do Not Use With 7543A) DEALER CODING CONDITION BASIC PART NO. CODE 7A543 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4408 Clutch Master Cylinder: Specifications Clutch master cylinder nuts ................................................................................................................. ..................................................... 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4409 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Removal and Installation 1. Disconnect the clutch master cylinder rod from the clutch pedal. 2. Remove the clutch pedal bracket nut. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it immediately with water. Disconnect the clutch master cylinder hose from the clutch master cylinder and plug it to prevent excess fluid loss Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4410 4. Disconnect the clutch slave cylinder tube from the clutch master cylinder. 5. Remove the clutch master cylinder. 1 Remove the clutch master cylinder nut. 2 Remove the clutch master cylinder 6. To install reverse the removal procedure ^ Bleed the air from the system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Clutch slave cylinder bolts ................................................................................................................... ..................................................... 20 Nm (15 ft. lbs.) Clutch slave cylinder tube nut .......................... ......................................................................................................................................... 25 Nm (18 ft. lbs.) Clutch slave cylinder tube fitting .............................................................................................................................................................. 30 Nm (22 ft. lbs.) Clutch slave cylinder line bracket bolts .................................................................................................................................................... 20 Nm (15 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4414 Clutch Slave Cylinder: Service and Repair Slave Cylinder Removal and Installation 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it immediately with water. Disconnect the clutch slave cylinder tube and plug it to prevent excess fluid loss. 2. Remove the clutch slave cylinder 1 Remove the clutch slave cylinder bolts 2 Remove the clutch slave cylinder 3. To install reverse the removal procedure ^ Bleed the air from the system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch pedal disengagement height mm (inch) ........................................................................................................................................... 59 mm (2.3 inch) Clutch pedal free play mm (inch) ....................................................................................................................................... 506 - 15.0 mm (0.22 - 0.59 inch) Clutch pedal height mm (inch) ............................................................................................................................................ 212 - 217 mm (8.35 - 8.54 inch) Clutch pedal bracket bolt and nuts ............................................................................................................................................................ 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 4418 Clutch Pedal Assembly: Service and Repair Clutch Pedal Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the clutch master cylinder nut. 3. Disconnect the electrical connectors. 4. Disconnect the clutch master cylinder rod from the clutch pedal. 5. Remove the clutch pedal. 1 Remove the nuts. 2 Remove the clutch pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 4419 6. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Clutch Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Clutch Switch > Page 4424 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 4427 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair Clutch Release Fork: Service and Repair Clutch Release Fork Removal and Installation 1. Remove the transaxle 2. Remove the rubber boot 3. Remove the clutch release fork and bearing 4. To install, reverse the removal procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Pilot Bearing Special Tools Special Tool(s) Removal 1. Remove the flywheel. 2. Inspect the pilot bearing for: ^ misalignment and looseness in the crankshaft ^ needle rollers for scoring, worn or broken rollers, inadequate grease or discoloration ^ seal leakage 3. NOTE: Install a new pilot bearing only if it is damaged. Using the special tool, remove the pilot bearing. 1 Install the special tool. 2 Remove the pilot bearing. 4. Clean the transaxle input shaft with a wire brush. 5. Inspect the transmission input shaft for: ^ burrs ^ rust ^ damage to the input shaft spline ^ damage to the input shaft on the pilot bearing contact surface Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 4434 1. Using the special tool, install the pilot bearing 2. Apply a light coating of Premium Long-Life Grease XG-1-C, XG-1-K or equivalent meeting Ford specification ESA-M1C75-B to the transaxle input shaft 3. Install the flywheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure plate side .............................................................................................................................. ................................................... 3.5 mm (0.138 inch) Clutch pressure plate bolts .................................................................................................................. ...................................................... 29 Nm (21 ft. lbs.) Pressure plate diaphragm spring fingers Maximum depth ................................................................................................................................... .............................................. 0.5 mm (0.020 inch) Maximum clearance ............................................ ............................................................................................................................... 0.5 mm (0.020 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4438 Pressure Plate: Service and Repair Clutch Disc and Pressure Plate Special Tool(s) Removal WARNING: Clutches and brakes contain asbestos fibers. Avoid breathing dust. Breathing asbestos dust may cause asbestosis and cancer. Failure to follow these instructions may result in personal injury. Breathing asbestos dust is hazardous to your health. Failure to follow these instructions may result in personal injury. Dust and dirt present on wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing. Failure to follow these instructions may result in personal injury. Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum 164-R3600. Dust and dirt from vacuum should be disposed of in a manner that prevents dust exposure such as sealed bags. The bag must be labeled as per OSHA instructions and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. Grinding or sanding on brake linings, pads, rotors, drums or clutch facings should be done only while using correctly exhaust-ventilated equipment. Failure to follow these instructions may result in personal injury. OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with carrying out brake or clutch service should be present in the area. Failure to follow these instructions may result in personal injury. 1. Remove the transaxle 2. Using the special tool lock the flywheel to the engine Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4439 3. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury. CAUTION: Loosen bolts evenly to prevent pressure plate damage. Remove the bolts, clutch pressure plate, and clutch disc 4. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Using a suitable commercial alcohol base solvent, clean the clutch pressure plate 5. Inspect the clutch pressure plate surface for burn marks, scores flatness or ridges 6. Inspect the clutch pressure plate diaphragm fingers for wear. Install a new clutch pressure plate as necessary 7. Measure the depth to the rivet heads. Install a new clutch disc if any rivet head measurement is not within specifications. 8. CAUTION: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation. NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface. Install a new clutch disc if any of the following conditions are present. Inspect the clutch disc for: ^ oil or grease saturation ^ worn or loose facings ^ warpage or loose rivets at the hub ^ loose or broken torsion dampening springs ^ wear or rust on splines Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4440 9. Using the special tool, check clutch disc runout. Install a new clutch disc if not within specifications. 10. NOTE: Install a new clutch release fork if any of the following conditions are present. Inspect the clutch release fork for: ^ cracks ^ distortion ^ excessive wear on the release bearing contact surface Installation 1. Using the special tool, position the clutch disc on the flywheel. 2. Position the clutch pressure plate on the flywheel, install the pressure plate bolts and tighten them in sequence to specification. 3. Remove the special tool. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4441 4. Remove the special tool. 5. Install the transaxle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Specifications Differential Carrier: Specifications Maximum aluminum carrier spread ..................................................................................................................................................... 0.25 mm (0.010 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Differential housing cover retaining bolt .................................................................................................................................................. 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4453 Differential Cover: Service and Repair Differential Housing Cover Removal 1. Raise and support the vehicle. 2. NOTE: Drain the differential fluid into a suitable drain pan. Remove the bolts and the rear differential cover. ^ Drain the differential fluid from the housing. Installation 1. CAUTION: Make sure the machined surfaces on the rear axle housing, the differential housing cover and the rotary blade coupling housing are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surfaces of the differential housing, the differential housing cover and the rotary blade coupling housing. 2. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured. Apply a new continuous bead of clear silicone rubber as shown in the illustration. 3. Install the differential housing cover and bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 4454 4. Fill the rear axle with 1.4 liters (2.95 pints) of rear axle lubricant. ^ Tighten the filler plug. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications Differential Axle Housing: Specifications Differential housing-to-front insulator bracket bolts ................................................................................................................................. 80 Nm (59 ft. lbs.) Differential housing-to-side insulator bracket bolts .................................................................................................................................. 80 Nm (59 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Filler plug ............................................................................................................................................. .................................................... 27 Nm (20 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications Differential Oil Capacity Refill...................................................................................................................................................... ............................................... 1.4 Liters (2.95 Pints) Fill the rear axle 3-5 mm (1/8-3/16 inch) from the bottom of filler hole. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications Pinion bearing preload - (drive pinion collapsible spacer) used bearings ........................................................................... 0.68 - 1.13 Nm (6 - 10 inch lbs.) Pilot runout ........... .............................................................................................................................................................. ........ 0.15 mm (0.006 inch) max. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications Ring gear bolt ...................................................................................................................................... ................................................... 109 Nm (80 ft. lbs.) Backlash between ring gear and pinion teeth ................................................................................................................ 0.13 - 0.20 mm (0.005 0.008 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing and Seal Part 1 Of 2 Part 2 Of 2 Special Tool(s) Removal 1. Remove the halfshaft assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 4477 2. To remove the seal only, use the special tool and remove the stub shaft seal. 3. To remove the bearing and seal use the special tools and remove the stub shaft pilot bearing and seal. Installation 1. NOTE: Lubricate the new stub shaft pilot bearing with rear axle lubricant. To install the bearing, use the special tools and install the stub shaft pilot bearing. 2. NOTE: Lubricate the new stub shaft pilot bearing housing seal with grease. To install the seal, use the special tools and install the stub shaft pilot bearing housing seal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 4478 3. CAUTION: Inspect the inboard CV joint seal journal for rust or nicks/scratches prior to installing the halfshaft. If necessary, polish the seal journal with fine crocus cloth. Install the halfshaft assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft Assembly: > 05-10-7 > May > 05 > Drivetrain - Whine Noise at 20-45 MPH Axle Shaft Assembly: Customer Interest Drivetrain - Whine Noise at 20-45 MPH TSB 05-10-7 05/30/05 DRIVELINE WHINE 20-45 MPH (32-72 KM/H) FORD: 2001-2006 Escape MERCURY: 2005-2006 Mariner ISSUE Some 2001-2006 Escape and 2005-2006 Mariner vehicles equipped with a CD4E transaxle may exhibit a driveline whine at 20-45 MPH (32-72 Km/h) during light acceleration or deceleration. The sound may be more pronounced on vehicles equipped with steel wheels. ACTION If the whine noise occurs at the specified speed range 20-45 MPH (32-72 Km/h) during light acceleration or deceleration, install new dampened halfshaft assemblies. The revised halfshafts are designed to minimize the whine, however, a small amount of noise may be inherently characteristic. The dampened axle halfshafts will not correct driveline noises below or above 20-45 MPH (32-72 Km/h). Refer to Workshop Manual Section 307. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051007A 2001-2004 Escape 1.1 Hrs. Replace The Front Halfshafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) 051007B 2005-2006 Escape/Mariner 1.4 Hrs. Replace The Front Half shafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) DEALER CODING CONDITION BASIC PART NO. CODE 3A427 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft Assembly: > 05-10-7 > May > 05 > Drivetrain - Whine Noise at 20-45 MPH Axle Shaft Assembly: All Technical Service Bulletins Drivetrain - Whine Noise at 20-45 MPH TSB 05-10-7 05/30/05 DRIVELINE WHINE 20-45 MPH (32-72 KM/H) FORD: 2001-2006 Escape MERCURY: 2005-2006 Mariner ISSUE Some 2001-2006 Escape and 2005-2006 Mariner vehicles equipped with a CD4E transaxle may exhibit a driveline whine at 20-45 MPH (32-72 Km/h) during light acceleration or deceleration. The sound may be more pronounced on vehicles equipped with steel wheels. ACTION If the whine noise occurs at the specified speed range 20-45 MPH (32-72 Km/h) during light acceleration or deceleration, install new dampened halfshaft assemblies. The revised halfshafts are designed to minimize the whine, however, a small amount of noise may be inherently characteristic. The dampened axle halfshafts will not correct driveline noises below or above 20-45 MPH (32-72 Km/h). Refer to Workshop Manual Section 307. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051007A 2001-2004 Escape 1.1 Hrs. Replace The Front Halfshafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) 051007B 2005-2006 Escape/Mariner 1.4 Hrs. Replace The Front Half shafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) DEALER CODING CONDITION BASIC PART NO. CODE 3A427 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications Axle Shaft Assembly: Mechanical Specifications General Specifications General Specifications Torque Specifications Torque Specifications General Specifications General Specifications Torque Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 4495 Axle Shaft Assembly: Fluid Type Specifications Front Drive Halfshafts High Temperature Constant Velocity Joint Grease E43Z-19590-A ........................................................................................................ ESP-M1C207-A Rear drive Halfshafts Constant Velocity Joint Grease (High Temp) E43Z-19590-A ................................................................................................................. ESP-M1C207-A Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshaft Axle Shaft Assembly: Description and Operation Front Drive Halfshaft Front Drive Halfshafts The front wheel drive halfshafts consist of the following components: ^ inboard CV joints ^ outboard CV joints ^ intermediate shaft/bearing ^ halfshaft The intermediate shaft contains a pressed on bearing which is can only be repaired as an assembly. Halfshaft Joint The front wheel halfshaft joints consist of the following components: ^ inboard CV joints ^ outboard CV joints ^ halfshaft joint boot clamps ^ halfshaft joint boots ^ tripod joint housings ^ retainer circlips Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshaft > Page 4498 Axle Shaft Assembly: Description and Operation Rear Drive Halfshaft Rear Drive Halfshafts CAUTION: An inspection of the outer and inner boots is necessary so that if damage or grease leakage is evident, installation of a new halfshaft can take place immediately. Continued operation with damage or grease leakage will result in CV joint wear and noise due to contamination and loss of the CV joint grease. ^ The RH and LH halfshafts are the same length. ^ Inboard and outboard CV joints connect to a splined shaft. A circlip stopper holds the cross groove inboard race assembly (inboard CV joint) together. ^ An axle circlip retains the splined inboard CV joint to the differential side gear. Install a new axle circlip each time the halfshaft is removed from the vehicle ^ A rear axle wheel hub nut secures the side shaft assembly (interconnecting shaft and outboard CV joint) to the rear hub. Install a new rear axle wheel hub nut each time the halfshaft is removed from the vehicle. Halfshaft Handling CAUTION: Never pick up or hold the halfshaft only by the inboard or outboard CV joint. Do not over-angle the CV joints. Damage will occur to an assembled inboard CV joint if it is over-plunged outward from the joint housing. Never use a hammer to remove or install the halfshafts. Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. Do not allow the boots to contact sharp edges or hot exhaust components. Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Handle all halfshaft components carefully during removal and installation procedures. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft Axle Shaft Assembly: Service and Repair Removal and Installation, Front Drive Half Shaft Halfshaft Special Tools Special Tool(s) Removal NOTE: RH shown; LH similar. 1. Remove the front wheels and tires. 2. Remove and discard the front axle wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4501 3. Remove the clip. 4. Separate the lower control arm from the front wheel knuckle. 1 Remove the pinch bolt and nut. 2 Separate the lower control arm from the front wheel knuckle. 5. Using the special tool, separate the halfshaft from the front wheel knuckle. 6. Using the special tools, remove the halfshaft. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4502 1. NOTE: When seated correctly, the driveshaft bearing retainer circlip can be felt as it snaps into the differential side gear groove. Position the front wheel driveshaft and joint so the splines line up with the differential side gear splines. Push the front wheel driveshaft and joint into the differential side gear. 2. Using the special tool, position the halfshaft into the front wheel knuckle. 3. Install the lower control arm and the ball joint pinch bolt and nut. 4. Install the clip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4503 5. Install a new front axle wheel hub nut. 6. Install the front wheels and tires. 7. Check and refill the transaxle fluid. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4504 Axle Shaft Assembly: Service and Repair Removal and Installation, Intermediate Shaft Intermediate Shaft Removal and Installation 1. Remove the RH front drive halfshaft. 2. Remove the two inner halfshaft bearing retainer nuts. 3. Remove the inner halfshaft. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4505 Axle Shaft Assembly: Service and Repair Disassembly and Assembly, Front Drive Half Shaft Halfshaft Special Tools Special Tool(s) Disassembly 1. Remove the halfshaft. 2. Secure the Halfshaft and Constant Velocity (CV) joint in a vise using protective jaw covers. 3. Remove the inboard halfshaft boot clamps. 4. Slide the inboard halfshaft boot off the inboard CV joint housing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4506 5. Separate the tripod joint from the inboard CV joint housing. 6. If reinstalling the original tripod joint, mark the tripod joint and the halfshaft to make sure of correct installation. 7. Remove the snap ring. 8. Remove the tripod joint. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4507 9. Remove the snap ring. 10. Remove the inboard halfshaft boot from the halfshaft. 11. Remove the two outboard halfshaft boot clamps. 12. Slide the outboard halfshaft joint boot back out of the way exposing the outboard CV joint. 13. If reinstalling the original outboard CV joint, mark the outboard CV joint and halfshaft to make sure of correct installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4508 14. Use a soft-face hammer to separate the outboard CV joint by gently tapping it off the halfshaft. 15. Remove the halfshaft bearing retainer circlip and discard. 16. Slide the outboard halfshaft boot off of the halfshaft. Assembly NOTE: Make sure all components are clean and free of foreign material. 1. Lubricate the outboard CV joint with Ford High Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4509 2. Install the outboard halfshaft boot. 3. Install a new halfshaft shaft bearing retainer circlip. 4. Use a soft-face hammer to install the outboard CV joint by gently tapping it onto the halfshaft. 5. Remove any excess grease on the mating surfaces and slide the outboard halfshaft joint boot forward onto the outboard CV joint. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4510 6. Remove any excess air trapped in the outboard halfshaft boot using a cloth covered screwdriver after adjusting the outboard halfshaft boot spacing. 7. Using the special tool, install two new outboard halfshaft boot clamps. 8. Position the inboard halfshaft boot. 9. Install the snap ring. 10. Install the tripod joint on the halfshaft. 1 Line up the marks on the halfshaft and tripod joint. 2 Install the tripod joint on the halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4511 11. Install the snap ring. 12. Lubricate the three tripod joint needle bearings. ^ Use Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207A. 13. Fill the tripod joint housing with Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207A. 14. Position the tripod housing onto the tripod. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4512 15. Position the inboard halfshaft boot. 1 Position the inboard halfshaft boot. 2 Position the inboard halfshaft boot clamp. 16. Remove any excess air trapped in the halfshaft boot using a cloth covered screwdriver after adjusting the halfshaft boot spacing. 17. Using the special tool, install two new outboard joint boot clamps. 18. Remove the halfshaft from the vise. 19. Install the front wheel halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4513 Axle Shaft Assembly: Service and Repair Removal and Installation, Rear Drive Half Shaft Halfshaft Special Tool(s) Removal 1. Remove the rear coil spring. 2. Remove and discard the nut. 3. CAUTION: Make sure to support the wheel knuckle. Remove the nut and separate the lower ball joints. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4514 4. Using the special tool, separate the halfshaft from the knuckle. 5. Using the special tool, remove the halfshaft. Installation 1. Install the halfshaft into the differential. 2. Using the special tool, install the halfshaft end into the hub assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4515 3. Position the lower ball joint and install the nut. 4. Install the halfshaft nut. 5. Install the rear coil spring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4516 Axle Shaft Assembly: Service and Repair Disassembly and Assembly, Rear Half Shaft Joint Halfshaft Joint Special Tools Special Tool(s) Disassembly 1. Remove the halfshaft. 2. Secure the halfshaft and Constant Velocity (CV) joint in a vise using protective jaw covers. 3. Remove the inboard halfshaft boot clamps. 4. Slide the inboard halfshaft boot off the inboard CV joint housing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4517 5. If reinstalling the original inner joint, mark the inner joint and the halfshaft to make sure of correct installation. 6. Using a soft face hammer, separate the halfshaft from the inboard joint housing. 7. Remove and discard the bearing retainer circlip. 8. Remove and discard the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4518 9. Remove the inboard halfshaft boot from the halfshaft. 10. Remove the two outboard halfshaft boot clamps. 11. Slide the outboard halfshaft joint boot back out of the way exposing the outboard CV joint. 12. If reinstalling the original outboard CV joint, mark the outboard CV joint and halfshaft to make sure of correct installation. 13. Use a soft-face hammer to separate the outboard CV joint by gently tapping it off the halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4519 14. Remove the halfshaft bearing retainer circlip and discard. 15. Remove the snap ring from the halfshaft. 16. Slide the outboard halfshaft boot off of the halfshaft. Assembly 1. Lubricate the inboard and outboard CV joint with joint grease. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4520 2. Install the outboard halfshaft boot. 3. Install the snap ring on the halfshaft. 4. Install a new halfshaft shaft bearing retainer circlip. 5. Use a soft-face hammer to install the inboard CV joint by gently tapping it onto the halfshaft. 6. Remove any excess grease on the mating surfaces and slide the outboard halfshaft joint boot forward onto the outboard CV joint. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4521 7. Remove any excess air trapped in the outboard halfshaft boot using a cloth covered screwdriver after adjusting the outboard halfshaft boot spacing. 8. Using the special tool, crimp two new outboard halfshaft boot clamps. 9. Position the inboard halfshaft boot. 10. Install the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4522 11. Install the bearing retainer circlip. 12. Using a soft face hammer, install the halfshaft on the inboard joint. 13. Position the inboard halfshaft boot. 14. Remove any excess air trapped in the halfshaft boot using a cloth covered screwdriver after adjusting the halfshaft boot spacing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation, Front Drive Half Shaft > Page 4523 15. Using the special tool, install two new inboard joint boot clamps. 16. Install the front wheel halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection NOTE: The wheel bearings are not adjustable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4529 Removal NOTE: Install a new wheel bearing when the wheel hub is removed. All vehicles 1. Remove the brake disc. 2. Remove the wheel hub nut. 3. Remove the tie rod end nut. 1 Remove the cotter pin. 2 Remove the nut. 4. Using the special tool, separate the tie rod end from the knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4530 Vehicles with ABS 5. Remove the bolt and position the anti-lock brake sensor aside. All vehicles 6. Separate the lower ball joint from the wheel knuckle. 1 Remove the pinch bolt. 2 Separate the lower ball joint from the wheel knuckle. 7. Using the special tool, separate the halfshaft from the wheel knuckle. ^ Position the halfshaft aside and support. 8. Remove the wheel knuckle. 1 Remove the strut-to-wheel knuckle bolts. 2 Remove the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4531 9. Using the special tool, press the wheel hub from the wheel bearing and knuckle. 10. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 11. Remove the snap ring. 12. Using the special tools, press the outer wheel bearing race from the wheel knuckle. NOTE: The brake disc shield is pressed on. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4532 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4533 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. 1 Position the wheel knuckle. 2 Install the strut-to-wheel knuckle bolts. 6. Using the special tool, insert the halfshaft into the wheel hub. 7. Install the pinch bolt into the wheel knuckle. ^ Position and align the ball joint stud into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4534 Vehicles with ABS 8. Install the anti-lock brake sensor and tighten the bolt. All vehicles 9. Install the tie rod end into the wheel knuckle. 1 Install the tie rod end nut. 2 Install a new cotter pin. 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4535 Wheel Bearing: Service and Repair Rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4536 Special Tool(s) Removal 1. Remove the brake drum. 2. NOTE: If equipped, remove the ABS sensor ring. Remove the wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4537 3. Using the special tools, remove the wheel hub. 4. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 5. Remove the snap ring. 6. Using the special tools, remove the wheel bearing outer race from the wheel knuckle. Installation 1. Using the special tools, install the wheel bearing into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4538 2. Install the snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. 4. NOTE: If equipped, install the ABS sensor ring. Install the wheel hub nut. 5. Install the brake drum. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel hub nut ..................................................................................................................................... .................................................. 290 Nm (214 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications Driveshaft runout ................................................................................................................................. .................................................. 0.89 mm (0.03 inch) Driveshaft to power take off bolts ............................................................................................................................................................ 37 Nm (27 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4547 Drive/Propeller Shaft: Service and Repair Driveshaft Removal and Installation WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to remove any part of the system until it has cooled. Be especially careful when working around the catalytic converters. The temperature of the converter rises to a high level after only a few minutes of engine operation. Failure to follow these instructions may result in personal injury. Front driveshaft and driveshaft assembly 1. Place the selector lever in NEUTRAL 2. Raise and support the vehicle. Driveshaft assembly 3. Remove the ground strap bolt 4. CAUTION: Do not reuse the bolts and straps for the pinion yoke. Install new bolts and straps. NOTE: There is a difference in the length of the head of the replacement yoke strap bolts from the production bolts. The longer head pinion bolts can be used in either location. Remove the rear driveshaft universal joint caps 1 Index-mark the pinion and yoke to the rear of the driveshaft 2 Remove and discard the bolts and straps Front driveshaft and driveshaft assembly 5. CAUTION: Do not reuse the CV joint bolts and washers. Install new bolts and washers only or damage to the vehicle may occur. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4548 Remove the six front driveshaft to power take off bolts and washers ^ Discard the bolts and washers Driveshaft assembly 6. With the help of an assistant, remove the driveshaft. ^ Remove the center bearing nuts. Front driveshaft 7. CAUTION: Do not reuse the bolts and straps for the center U-joint. Install new bolts and straps or damage to the vehicle may occur. NOTE: There is a difference in the length of the head of the replacement yoke strap bolts from the production bolts. The longer head pinion bolts can be used in either location. Remove the front driveshaft. 1 Index-mark the front driveshaft to the center bearing. 2 Remove and discard the bolts and caps. Front driveshaft and driveshaft assembly 8. NOTE: If a driveshaft is installed and driveshaft vibration is encountered after installation, index the driveshaft. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications Universal Joint: Specifications Universal joint cap bolts ....................................................................................................................... .................................................... 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications > Page 4552 Universal Joint: Service and Repair Universal Joint - Center and Rear Special Tool(s) Removal and Installation CAUTION: Do not reuse the bolts and straps for either of the center U-joint or the pinion yoke U-joint. Install new bolts and straps or damage to the vehicle may occur. NOTE: There is a difference in length of the head of the replacement yoke strap bolts from the production bolts. The longer head pinion bolts can be used in either location. 1. NOTE: Index the driveshaft yoke to the driveshaft. Remove the driveshaft. 2. Clamp the special tool into a vise. 3. Remove the snap rings. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Specifications > Page 4553 4. Press out the bearing cups. ^ Rotate the driveshaft 180 degrees and repeat. 5. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel bolts ...................................................................................................................................... ................................................... 112 Nm (83 ft. lbs.) Transaxle flywheel housing to engine bolts .............................................................................................................................................. 45 Nm (33 ft. lbs.) Flywheel runout Maximum runout .................................................................................................................................. ................................................ 0.2 mm (0.008 in.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 4557 Flywheel: Service and Repair Flywheel Removal 1. Remove the clutch. 2. Remove the bolts and the flywheel. 3. To Stall, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair SELECTOR LEVER INDICATOR BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the selector lever indicator bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Case cover bolts .................................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Transaxle case to flywheel housing bolts .................................................................................................................................................. 45 Nm (33 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Service and Repair Ring Gear: Service and Repair Flywheel Ring Gear Removal WARNING: This procedure should be carried out only by a correctly equipped and experienced acetylene torch operator. To avoid personal injury, tongs must be used or asbestos gloves worn when handling the heated flywheel ring gear. Failure to follow these instructions may result in personal injury. 1. Remove the flywheel. 2. CAUTION: Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel. ^ Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the flywheel Installation WARNING: This procedure should be carried out only by a correctly equipped and experienced acetylene torch operator. To avoid personal injury, tongs must be used or asbestos gloves worn when handling the heated flywheel ring gear. Failure to follow these instructions may result in personal injury. 1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (532°F). Use heat indicating crayons to prevent overheating. Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring gear 2. CAUTION: The bevel on the flywheel ring gear must face the rear of the flywheel. Install the flywheel ring gear. ^ Use a brass drift to tap the flywheel ring gear into position. 3. Install the flywheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain plug ............................................................................................................................................ ..................................................... 47 Nm (35 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.8 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4578 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type Type ..................................................................................................................................................... .................. Motorcraft SAE 75W-90 Gear Oil GL-4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Halfshaft Oil Seal Special Tool(s) Removal 1. Remove the halfshaft. 2. NOTE: RH side shown, LH side similar. Remove the halfshaft seal. Installation 1. NOTE: RH side shown, LH side similar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Page 4582 Using the special tool, install the new halfshaft seal. 2. Install the halfshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) bolt ............................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4587 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the bolt and the VSS. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Gearshift lever bolts ............................................................................................................................. ..................................................... 23 Nm (17 ft. lbs.) Stabilizer bar to transaxle bolt .......................... ........................................................................................................................................ 40 Nm (30 ft. lbs.) Gearshift stabilizer bar to transaxle bolt ................................................................................................................................................... 40 Nm (30 ft. lbs.) Gearshift stabilizer bar to vehicle body nuts ............................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Stabilizer Bar Bushing Shifter M/T: Service and Repair Gearshift Stabilizer Bar Bushing Gearshift Stabilizer Bar Bushing Removal and Installation 1. Remove the gearshift stabilizer bar bolt. 2. Remove the gearshift stabilizer bar bushing. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Stabilizer Bar Bushing > Page 4593 Shifter M/T: Service and Repair Gearshift Stabilizer Bar Gearshift Stabilizer Bar Removal and Installation 1. Remove the gearshift lever. 2. Lower the vehicle. 3. Remove the nuts. 4. Raise and support the vehicle. 5. Remove the gearshift stabilizer bar bolt. 6. Remove the Gearshift stabilizer bar from the vehicle. 7. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Stabilizer Bar Bushing > Page 4594 Shifter M/T: Service and Repair Gearshift Lever Gearshift Lever - 4X2 Removal and Installation 1. Remove the center console trim and gearshift lever boot. 1 Remove the gearshift lever knob. 2 Remove the center console trim and gearshift lever boot. 2. Remove the snap ring. 3. Remove the plastic clip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Stabilizer Bar Bushing > Page 4595 4. Remove the rubber bushing. 5. Raise and support the vehicle. 6. Disconnect the gearshift linkage. 1 Remove the bolt and nut. 2 Disconnect the gearshift linkage. 7. Remove the gearshift lever. 8. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Stabilizer Bar Bushing > Page 4596 Shifter M/T: Service and Repair Gearshift Lever Boot Gearshift Lever Boot Removal and Installation 1. Remove the center console trim and gearshift lever boot. 1 Remove the gearshift lever knob. 2 Remove the center console trim and gearshift lever boot. 2. Remove the gearshift lever boot. 1 Remove the screws. 2 Remove the gearshift lever boot. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications Shift Cable: Specifications Gearshift cable to underbody bracket bolts ............................................................................................................................................. 9 Nm (80 inch lbs.) Gearshift cable bracket to interior body bolts ........................................................................................................................................... 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) bolt ............................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4604 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the bolt and the VSS. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4610 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4611 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4617 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4618 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4619 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4620 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4621 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4622 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine Shaft Speed (TSS) sensor bolt .................................................................................................................................................... 13 Nm (10 ft. lbs.) Output Shaft Speed (OSS) sensor bolt ..................................................................................................................................................... 13 Nm (10 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4628 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Connector Output Shaft Speed (OSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4631 Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor Connector Turbine Shaft Speed (TSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4632 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4633 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Remove the Output Shaft Speed (OSS) sensor. ^ Disconnect the OSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the OSS bore. 5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4636 1. NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Install the OSS sensor. ^ Connect the OSS sensor electrical connector. 2. Install the splash shield. 3. Install the LH front wheel. 4. Lower vehicle. 5. Check the transmission fluid level, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 6. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4637 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Place a drain pan beneath the Turbine Shaft Speed (TSS) sensor. 5. Remove the TSS sensor. ^ Disconnect the TSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the TSS sensor bore. 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4638 1. NOTE: Apply a light coat of petroleum jelly to the O-ring seal before installation. Install the TSS sensor. ^ Connect the TSS electrical connector (white connector). 2. Remove the drain pan. 3. Install the splash shield. 4. Install the LH front wheel. 5. Lower the vehicle. 6. Check the transmission fluid level, add fluid as necessary using clean automatic transmission fluid. 7. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) bolt ............................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4643 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the bolt and the VSS. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Specifications Transfer Case: Specifications Transfer Case Capacity SAE 75W-140 Synthetic Gear Lubricant ...................................................................................................................................................... 0.35l (12 oz.) Note: The fluid level must be even with the bottom of the filler hole. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair SELECTOR LEVER INDICATOR BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the selector lever indicator bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4667 Shift Interlock Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Diagrams > Page 4668 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Transmission Range (TR) sensor bolts ....................................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4674 View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4675 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4676 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. Place the vehicle in NEUTRAL. 2. Disconnect the battery cables. 3. Remove the battery and tray. 4. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 5. Remove the intake tube and air cleaner cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4677 6. Remove the air cleaner assembly. 7. NOTE: It may be necessary to remove the thermostat housing to gain access to the Transmission Range (TR) sensor. Remove the thermostat housing. 8. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the Transmission Range (TR) sensor and loosely install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4678 2. Using the special tool align the TR sensor and tighten the bolts. ^ Connect the electrical connector. 3. Install the thermostat housing. 4. Install the air cleaner assembly. 5. Install the intake tube and air cleaner cover. 6. Connect the breather tube and Mass Air Flow (MAF) sensor. 7. NOTE: Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position. Install the battery and tray. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4679 Connect the battery cables. 9. Check the correct operation with parking brake control engaged. The engine should start only in PARK or NEUTRAL. Backup lamps should be active only in the REVERSE position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine Shaft Speed (TSS) sensor bolt .................................................................................................................................................... 13 Nm (10 ft. lbs.) Output Shaft Speed (OSS) sensor bolt ..................................................................................................................................................... 13 Nm (10 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed Sensor > Page 4685 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Connector Output Shaft Speed (OSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4688 Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor Connector Turbine Shaft Speed (TSS) Sensor Connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4689 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Connector > Page 4690 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Remove the Output Shaft Speed (OSS) sensor. ^ Disconnect the OSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the OSS bore. 5. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4693 1. NOTE: Apply a light coat of petroleum jelly to the O-ring before installation. Install the OSS sensor. ^ Connect the OSS sensor electrical connector. 2. Install the splash shield. 3. Install the LH front wheel. 4. Lower vehicle. 5. Check the transmission fluid level, add fluid as necessary using MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON(R) V specification. 6. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4694 Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal 1. Raise and support the vehicle. 2. Remove the LH front wheel. 3. Remove the splash shield. 4. Place a drain pan beneath the Turbine Shaft Speed (TSS) sensor. 5. Remove the TSS sensor. ^ Disconnect the TSS sensor electrical connector. ^ Remove the bolt. ^ Inspect the TSS sensor bore. 6. Inspect the O-ring seal for nicks or cuts. Install a new seal as necessary. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4695 1. NOTE: Apply a light coat of petroleum jelly to the O-ring seal before installation. Install the TSS sensor. ^ Connect the TSS electrical connector (white connector). 2. Remove the drain pan. 3. Install the splash shield. 4. Install the LH front wheel. 5. Lower the vehicle. 6. Check the transmission fluid level, add fluid as necessary using clean automatic transmission fluid. 7. Start the engine and move the transaxle range selector lever through all gear positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle Speed Sensor (VSS) bolt ............................................................................................................................................................ 7 Nm (62 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 4700 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the bolt and the VSS. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair Technical Service Bulletin # 07S51S2 Date: 091009 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4717 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated April 10, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website. Owner names and addresses were made available April 30, 2007. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4718 NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles have been directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 07S51 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES If an ABS module needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Handling Allowance: An allowance of $1.00 per repair is being provided to cover the costs of locally obtained materials and XG-12 Electrical Grease. To claim the allowance, enter $1.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4719 ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4720 Parts will not be direct shipped for this program Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50376. Questions regarding parts should be directed to the Special Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected ABS Modules (Part number YL8Z-2C065-AA and YL8Z-2B373-BA) and the removed ABS connector are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector. During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number. If the ABS module is corroded, the ABS module and connector must be replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4721 A flow chart has been developed to help direct you to the proper repair. See Figure 1. Inspect Connector Seals INSPECTION 1. Disconnect the battery negative terminal. 2. NOTE: When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed. Disconnect the ABS module 25-pin connector by sliding the lock mechanism out (towards the passenger side of the vehicle) and pulling the connector off the module. 3. Disconnect the speed sensor harness, then remove the 2 harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection. 4. Inspect the top of the ABS module connector cover for 2 yellow "X" marks. ^ If 2 yellow "X" marks are present, perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. ^ If no yellow "X" marks are present, proceed to Step 5. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4722 5. Inspect the ABS module connector pins for corrosion. See Figure 2. ^ If corrosion is present, perform Labor Operation E - Install Pigtail, New ABS Module and Apply Electrical Grease. ^ If corrosion is not present, proceed to Step 6. 6. CAUTION: Do not cut any of the harness wires or the wire insulation when cutting off the tie strap. Remove the tie strap from the connector dress cover, then slide the cover off the connector. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4723 7. Verify the wire seals are present on the 4 heavier gauge wires. See Figure 4. 8. Verify the numbers 054" are stamped on the slide-lock end of the mat cover (wipe the mat cover clean if necessary to view). See Figure 5. NOTE: Mat covers with any other number will be missing plugs in the unused pin locations. 9. Perform Labor Operation C - Install Pigtail and Apply Electrical Grease if: ^ any seals are missing or, ^ if the number on the mat cover is not "054". 10. Perform Labor Operation D - Seat Connector and Apply Electrical Grease if: ^ Any of the 4 wire seals are not fully seated in the connector cavities. ^ Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. See Figure 4. 11. Perform Labor Operation A - Apply Electrical Grease if: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4724 ^ The module is not corroded. and ^ All seals are present. and ^ All seals are fully seated. and ^ The number on the mat cover is "054". LABOR OPERATION A - APPLY ELECTRICAL GREASE 1. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 6. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 6. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 3. Reconnect the battery negative terminal. LABOR OPERATION C - INSTALL PIGTAIL AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4725 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 7. 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 8. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 8. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4726 3. Strip approximately 6 mm (1/2 in) of insulation from each of the cut wires in the harness. See Figure 9. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4727 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 10. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 11. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4728 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 12. 8. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 13. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4729 connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 13. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 9. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 10. Reconnect the battery negative terminal. 11. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION D - SEAT CONNECTOR SEALS AND APPLY ELECTRICAL GREASE 1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool. DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal. See Figure 14. 2. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4730 b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 15. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 15. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 4. Reconnect the battery negative terminal. LABOR OPERATION E - INSTALL PIGTAIL, NEW ABS MODULE AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4731 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 16. PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 17. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 17. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4732 3. Strip approximately 6 mm (1/4 in) of insulation from each of the cut wires in the harness. See Figure 18. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4733 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 19. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 20. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4734 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 21. 8. Install a new ABS module. Perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. 9. Reconnect the battery negative terminal. 10. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION F - INSTALL NEW ABS MODULE AND APPLY ELECTRICAL GREASE NOTE: Module configuration or reprogramming is not required when installing a new ABS module. 1. Disconnect the 2-wire electrical connector at the ABS module. 2. Raise the vehicle on a hoist. 3. Remove the screws and the ABS module. 4. Position the new module and install the screws. Tighten the screws no more than 2 Nm (18 lb-in). 5. Lower the hoist. 6. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4735 ^ Use ONLY Motorcraft Electrical Grease XG-12. See Figure 22. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 22. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 7. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 8. Reconnect the 2-wire connector to the ABS module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4736 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4737 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4738 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4739 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4740 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4741 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA07V156000 > Mar > 07 > Recall 07V156000: ABS Module Connector Defect Electronic Brake Control Module: Recalls Recall 07V156000: ABS Module Connector Defect MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V156000 MFR'S REPORT DATE: March 30, 2007 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 446460 SUMMARY: On certain sport utility vehicles equipped with Antilock Brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short. CONSEQUENCE: An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated. Remedy: Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on April 23, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S51. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair Technical Service Bulletin # 07S51S2 Date: 091009 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4751 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated April 10, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website. Owner names and addresses were made available April 30, 2007. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4752 NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles have been directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 07S51 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES If an ABS module needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Handling Allowance: An allowance of $1.00 per repair is being provided to cover the costs of locally obtained materials and XG-12 Electrical Grease. To claim the allowance, enter $1.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4753 ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4754 Parts will not be direct shipped for this program Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50376. Questions regarding parts should be directed to the Special Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected ABS Modules (Part number YL8Z-2C065-AA and YL8Z-2B373-BA) and the removed ABS connector are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector. During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number. If the ABS module is corroded, the ABS module and connector must be replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4755 A flow chart has been developed to help direct you to the proper repair. See Figure 1. Inspect Connector Seals INSPECTION 1. Disconnect the battery negative terminal. 2. NOTE: When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed. Disconnect the ABS module 25-pin connector by sliding the lock mechanism out (towards the passenger side of the vehicle) and pulling the connector off the module. 3. Disconnect the speed sensor harness, then remove the 2 harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection. 4. Inspect the top of the ABS module connector cover for 2 yellow "X" marks. ^ If 2 yellow "X" marks are present, perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. ^ If no yellow "X" marks are present, proceed to Step 5. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4756 5. Inspect the ABS module connector pins for corrosion. See Figure 2. ^ If corrosion is present, perform Labor Operation E - Install Pigtail, New ABS Module and Apply Electrical Grease. ^ If corrosion is not present, proceed to Step 6. 6. CAUTION: Do not cut any of the harness wires or the wire insulation when cutting off the tie strap. Remove the tie strap from the connector dress cover, then slide the cover off the connector. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4757 7. Verify the wire seals are present on the 4 heavier gauge wires. See Figure 4. 8. Verify the numbers 054" are stamped on the slide-lock end of the mat cover (wipe the mat cover clean if necessary to view). See Figure 5. NOTE: Mat covers with any other number will be missing plugs in the unused pin locations. 9. Perform Labor Operation C - Install Pigtail and Apply Electrical Grease if: ^ any seals are missing or, ^ if the number on the mat cover is not "054". 10. Perform Labor Operation D - Seat Connector and Apply Electrical Grease if: ^ Any of the 4 wire seals are not fully seated in the connector cavities. ^ Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. See Figure 4. 11. Perform Labor Operation A - Apply Electrical Grease if: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4758 ^ The module is not corroded. and ^ All seals are present. and ^ All seals are fully seated. and ^ The number on the mat cover is "054". LABOR OPERATION A - APPLY ELECTRICAL GREASE 1. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 6. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 6. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 3. Reconnect the battery negative terminal. LABOR OPERATION C - INSTALL PIGTAIL AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4759 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 7. 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 8. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 8. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4760 3. Strip approximately 6 mm (1/2 in) of insulation from each of the cut wires in the harness. See Figure 9. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4761 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 10. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 11. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4762 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 12. 8. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 13. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4763 connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 13. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 9. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 10. Reconnect the battery negative terminal. 11. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION D - SEAT CONNECTOR SEALS AND APPLY ELECTRICAL GREASE 1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool. DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal. See Figure 14. 2. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4764 b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 15. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 15. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 4. Reconnect the battery negative terminal. LABOR OPERATION E - INSTALL PIGTAIL, NEW ABS MODULE AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4765 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 16. PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 17. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 17. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4766 3. Strip approximately 6 mm (1/4 in) of insulation from each of the cut wires in the harness. See Figure 18. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4767 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 19. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 20. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4768 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 21. 8. Install a new ABS module. Perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. 9. Reconnect the battery negative terminal. 10. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION F - INSTALL NEW ABS MODULE AND APPLY ELECTRICAL GREASE NOTE: Module configuration or reprogramming is not required when installing a new ABS module. 1. Disconnect the 2-wire electrical connector at the ABS module. 2. Raise the vehicle on a hoist. 3. Remove the screws and the ABS module. 4. Position the new module and install the screws. Tighten the screws no more than 2 Nm (18 lb-in). 5. Lower the hoist. 6. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4769 ^ Use ONLY Motorcraft Electrical Grease XG-12. See Figure 22. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 22. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 7. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 8. Reconnect the 2-wire connector to the ABS module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4770 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4771 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4772 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4773 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4774 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4775 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA07V156000 > Mar > 07 > Recall 07V156000: ABS Module Connector Defect Electronic Brake Control Module: All Technical Service Bulletins Recall 07V156000: ABS Module Connector Defect MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V156000 MFR'S REPORT DATE: March 30, 2007 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 446460 SUMMARY: On certain sport utility vehicles equipped with Antilock Brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short. CONSEQUENCE: An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated. Remedy: Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on April 23, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S51. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4780 View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4781 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4782 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery negative cable. 2. Disconnect the electrical connectors. 3. Raise and support the vehicle. 4. Remove the screws and the control module. 5. NOTE: The 4x2 module cannot be interchanged with the 4x4 module. The 4x4 module is interchangeable with the 4x2 module. To install. reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Control module bolts1 .......................................................................................................................... ............................................ 1-2 Nm (9-17 inch lbs.) Hydraulic control unit (HCU) to bracket bolts ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4786 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery negative cable. 2. Remove the air cleaner and the air cleaner outlet pipe. 3. Disconnect the electrical connector 4. Disconnect the brake lines. 5. Remove the bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4787 6. Remove the bolts and the HCU. 7. NOTE: The 4x2 module cannot be interchanged with the 4x4 module. The 4x4 module is interchangeable with the 4x2 module. Remove the screws and the control module, if necessary. 8. NOTE: Bleed the HCU after performing this procedure. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Removal Tips Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Removal Tips TSB 04-23-2 11/29/04 WHEEL SPEED SENSOR REMOVAL TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE When servicing the wheel speed sensors on a 2001-2005 Escape or 2005 Mariner and Escape Hybrid, care must be taken during removal to prevent damage. The wheel speed sensor wire has a body plug attached to it. This plug can be damaged if not removed correctly, such as removal for pinpoint testing. If the body plug is damaged, sensor replacement may be necessary even though the sensor is functional in all other respects. ACTION When removing the body plug, rotate the plug into a position which allows the use of a small screwdriver to release the tabs on the underside of the body plug. These two tabs are at right angles (directly above and below) to the sensor wire. See Figures 1 and 2 for reference. WARRANTY STATUS: Information Only Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Removal Tips > Page 4792 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 4795 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 4796 View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 4797 View 151-28 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 4800 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 4801 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 4802 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 4803 Wheel Speed Sensor: Service and Repair Sensor-Front Removal and Installation 1. Remove the wheel and tire. 2. Detach the grommet from the body and pull the connector through the hole. 3. Disconnect the sensor wiring. 4. Detach the retainer. 5. Remove the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 4804 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel cylinder bleeder screws ............................................................................................................ .................................................... 8 Nm (71 inch lbs.) Bleeder screws ................................................ ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System Brake Bleeding: Service and Repair Bleeding - System Brake System Bleeding Special Tool(s) Anti-Lock Brakes Bleed NOTE: Bleeding the Hydraulic Control Unit (HCU) is required only when removing or installing the HCU or master cylinder, or opening the lines to the HCU. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the diagnostic tool. 2. Access the SYSTEM BLEED FUNCTION. Go to the Tool Tab-Chassis-Braking-ABS Service Bleed and follow the directions on the diagnostic tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of two diagnostic tool cycles and two manual bleed cycles. Manual Bleed Brake system WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. (let medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system alter it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel then to the RH front wheel and ending with the LH front wheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4810 Rear drum brakes 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 5. Loosen the bleeder screw until fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw. 6. Repeat Steps 4 and 5 until clear, bubble-free brake fluid flows. 7. Tighten the wheel cylinder bleeder screw. 8. Continue bleeding the rest of the system. Front disc brakes 9. Attach a rubber drain hose to the front disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 10. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 11. Loosen the front disc brake caliper bleeder screw until fluid flow stops. Maintain pressure on the brake pedal and tighten the front disc brake caliper bleeder screw. 12. Repeat Steps 10 and 11 until clear, bubble-free fluid flows. 13. Tighten the front disc brake caliper bleeder screw. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4811 14. Fill the brake master cylinder reservoir and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Gravity Bleed Brake system 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel, then to the RH front wheel and ending with the LH front wheel. Rear drum brakes 3. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Loosen the rear wheel cylinder bleeder screw and leave open until clear, bubble-free brake fluid flows. 4. Tighten the wheel cylinder bleeder screw. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4812 Front disc brakes 5. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Open the front disc brake caliper bleeder screw. Leave open until clear bubble-free brake fluid flows. 6. Tighten the front disc brake caliper bleeder screw. 7. Fill the brake master cylinder reservoir with fluid and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Brake System Pressure Bleeding Special Tool(s) WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4813 with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Clean the outside of the brake master cylinder reservoir. 2. Remove the reservoir cap and fill the brake master cylinder reservoir with brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 3. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install Brake Bleeder to the brake master cylinder reservoir, and attach the Brake Bleeder tank hose to the fitting on the adapter. 4. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 5. Open the valve on the Brake Bleeder tank. 6. Loosen the bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close the bleeder screw and remove the rubber hose. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4814 7. Tighten the wheel cylinder bleeder screw. 8. Continue bleeding the rest of the system, going in order from the LH rear wheel to the RH front wheel, ending with the LH front wheel. 9. Close the Brake Bleeder tank valve and remove the tank hose from the adapter, and remove the adapter. 10. Fill the brake master cylinder reservoir and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4815 Brake Bleeding: Service and Repair Bleeding - Components Component Bleeding Brake Master Cylinder-Bench Bleed WARNING: Use of any other than the approved DOT 3 brake will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed air may enter the system causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Support the brake master cylinder body in a soft jaw vise 2. Remove the master cylinder cap and install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir 3. NOTE: If equipped with a manual transmission plug the master cylinder feed port Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4816 Fill the brake master cylinder reservoir with High Performance DOT 3 brake fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A DOT 3 4. Slowly depress the primary piston until bubble -free brake fluid flows from both brake hoses 5. Remove the brake hoses from the master cylinder. 6. Install plugs in the front and rear brake outlet port. 7. Install the reservoir cap and install the brake master cylinder in the vehicle. ^ Remove the master cylinder outlet port plugs before installing the lines Brake Master Cylinder-In-Vehicle Bleed WARNING: Use of any other than the approved DOT 3 brake will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Disconnect the brake outlet lines from the brake master cylinder and cap the lines. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4817 2. Install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 4. Have an assistant pump the brake pedal until clear, bubble-free brake fluid flows from both brake hoses. 5. Remove the short brake hoses and install the brake outlet lines. 6. Bleed the hydraulic brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal Pedal free play ..................................................................................................................................... ..................................... 7.8-12 mm (0.3-0.47 inch) Brake pedal bracket nuts .................................... ................................................................................................................................... 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4821 Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Removal and Installation 1. Remove the Brake Pedal Position (BPP) switch. 2. If equipped, remove the speed control deactivator switch. 3. Disconnect the push rod from the brake pedal pin. ^ Remove the cotter pin and bushing. 4. Remove the brake pedal and bracket. ^ Remove the nuts. 5. To install reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc brake caliper bleeder screws ............................................................................................................................................................. 16 Nm (12 ft. lbs.) Front disc brake caliper bore mm (in) .................................................................... .............................................................................................. 60.0 (2.36) Brake caliper anchor plate bolts ........................................................................................................................................................... 150 Nm (111 ft. lbs.) Brake caliper bolts ............................................................................................. ....................................................................................... 35 Nm (26 ft. lbs.) Brake line to caliper ....... .............................................................................................................................................................. ............. 20 Nm (15 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation Brake Caliper: Service and Repair Caliper Removal and Installation Brake Caliper Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. 1. Remove the wheel and tire assembly. 2. Remove the brake caliper clip 3. Position the caliper aside 1 Remove the brake caliper bolt caps and bolts 2 Position the caliper aside 4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4828 with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component has been installed, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with a Brake Bleeder. Disconnect and cap the brake line from the caliper and remove the caliper. 5. CAUTION: Do no use denatured alcohol for flushing the brake system or cleaning assemblies where alcohol could be trapped. If denatured alcohol is trapped, it can cause eventual failure of rubber components in the system. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic systems. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all rubber seals and flex hoses replaced. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4829 Brake Caliper: Service and Repair Caliper Disassembly and Assembly Brake Caliper Disassembly 1. Remove front disc brake caliper from the vehicle. 2. Remove the front caliper slide pins and boots. 3. Remove the dust seal. 4. WARNING: Use only as much compressed air as necessary to remove the piston. Excessive pressure can force the piston out of the caliper bore with enough force to cause personal injury. Never attempt to catch the piston by hand as it comes out of the bore. Failure to follow these instructions may result in personal injury. CAUTION: Do not use a screwdriver or any other similar tool to pry the piston out of the bore. Piston damage could result. NOTE: Inspect the piston for wear, rust, or pits. If any of these conditions exist, a new piston must be installed. Remove the caliper piston. 1 Position a block of wood between the piston and the disc brake caliper. 2 Apply compressed air to caliper to remove piston. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4830 5. Remove the bleeder screw. 6. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak. NOTE: Inspect the caliper bore for wear, rust or pits If any of these conditions exist, do not hone; a new caliper must be installed Remove the piston seal. Assembly CAUTION: Do not use denatured alcohol to clean rubber components or assemblies that have rubber components. Cleaning rubber components with denatured alcohol weakens the rubber and may result in failure of the component. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic system. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all rubber seals and flex hoses replaced. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. NOTE: Be sure the seal is not twisted and is firmly seated in the caliper bore NOTE: Clean all brake caliper components. All parts must be air-dried completely Coat all internal parts and piston seal with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A. DOT 3 before installation. To assemble, reverse the disassembly procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4831 Brake Caliper: Service and Repair Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal and Installation 1. Remove the wheel and tire assembly. 2. Remove the brake caliper clip. 3. Position the caliper aside. 1 Remove the brake caliper bolt caps and the bolts. 2 Position the caliper aside and support. 4. Remove the outboard brake pad. 5. Remove the bolts and brake caliper anchor plate. 6. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake backing plate bolts .................................................................................................................... ..................................................... 66 Nm (49 ft. lbs.) Brake lining thickness ...................................... .................................................................................................................................... 12.75 mm (0.50 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 4835 Brake Pad: Service and Repair Brake Pads Removal WARNING: Asbestos fiber may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. 1. Remove the wheel and tire assembly. 2. Remove the brake caliper clip 3. Position the caliper aside 1 Remove brake caliper bolt caps and the bolts. 2 Position the caliper aside and support. 4. Remove the brake pads. ^ Remove the outer brake pad from the anchor ^ Remove the inner brake pad from the caliper piston 5. To install reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front Brake Rotor/Disc Rotor thickness mm (in) ....................................................................................................................... .......................................................... 24.00 (0.94) Rotor minimum thickness mm (in) ............................................................................................................................................................. 22.00 (0.8661) Rotor mount mm (in) ................................................................................................... ................................................................................... 0.05 (0.002) Front disc brake rotor Runout mm (in) ............................................................................................................................................................. 0.1 (0.004) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4839 Brake Rotor/Disc: Service and Repair Brake Disc 1. Remove the brake caliper anchor plate. 2. Remove the brake disc retaining clips (if equipped) and the brake disc. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Brake backing plate bolts .................................................................................................................... ..................................................... 66 Nm (49 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4844 Backing Plate: Service and Repair Brake Backing Plate Removal and Installation 1. Remove the rear wheel cylinder. 2. Remove the rear wheel hub. 3. Remove the parking brake cable from the brake backing plate. 1 Remove the bolt. 2 Remove the parking brake cable. 4. Remove the brake backing plate. 1 Remove the bolts. 2 Remove the brake backing plate. 5. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Brake Drum Maximum inside Diameter ......................................................................................................................................................... 230.10 mm (9.0590 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4848 Brake Drum: Service and Repair Brake Drum Special Tool(s) Removal WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos filters, such as brake/clutch/service vacuum. The bag must be labeled per the Occupational Safety and Health Act (OSHA) instructions, sealed, and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury. WARNING: If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The Occupational Safety and Health Act (OSHA) requires where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians carrying out brake or clutch repair are to be present in the area. Failure to follow these instructions may result in personal injury. CAUTION: To reduce the possibility of uneven braking, always install new rear brake shoes at both ends of an axle. 1. Remove the tire and wheel assembly. 2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result. NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum between the wheel studs. Remove the brake drum ^ If equipped, remove the brake drum retaining clips. 3. If the brake drums will not come off follow these steps. 1 Move the brake shoe adjusting lever off the brake adjuster screw 2 Loosen the brake shoe adjuster screw nut by adjusting the nut upward. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4849 4. Using the special tool. measure the brake drum inside diameter. ^ Install a new brake drum if the maximum inside diameter exceeds the specification shown on the outside of the brake drum. Installation 1. NOTE: If adjusting the rear brakes refer to Brake Shoe Adjustment. Position the brake drum on the vehicle. 2. WARNING: Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury. Clean the wheel hub mounting surface and wheel pilot. 3. Install the tire and wheel assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake shoe thickness Minimum mm (in) ................................................................................................................................. ................................................................ 1 (0.04) Standard mm (in) .................................................. .............................................................................................................................................. 4.5 (0.17) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4853 Brake Shoe: Adjustments Brake Shoe Adjustment Special Tool(s) 1. Remove the brake drum. 2. Using the special tool, measure the inside diameter of the brake drum. 3. Position the special tool on the brake shoes and linings and adjust accordingly. 4. Install the brake drum. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4854 Brake Shoe: Service and Repair Brake Shoes Special Tool(s) Removal and Installation 1. Remove the brake drum. 2. Use the Brake/Clutch/Service Vacuum to remove brake dust and dirt from the brake assemblies. 3. NOTE: If new rear brake shoes and linings are being installed. resurface the brake drums to remove glazing and to ensure an equal friction surface from side-to-side. Resurfacing wild also correct out-of-round and bell conditions. Inning the special tool, measure the braking surface diameter. If the inside diameter measures more than the maximum specification shown on the outside of the brake drum. install a new brake drum. 4. Remove the parking brake cable from the parking brake cable lever. 5. Remove the hold-down clips and pins. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4855 6. Remove the lower spring. 7. Remove the rear brake shoes. 1 Pull the bottom of the brake shoe forward. 2 Release the upper return spring. 3 Remove both brake shoes together. 8. Remove the self adjuster lever. 9. Remove the self adjuster and spring assembly. ^ Return the self adjuster to the fully seated position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4856 10. Remove the parking brake lever. 1 Remove the horseshoe clip. 2 Remove the parking brake lever. 11. Inspect the rear brake shoes for minimum thickness above the backing plate, and install new as necessary. 12. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel cylinder inner diameter mm (in) ............................................................................................................................................................ 23.81 (0.937) Brake line to rear wheel cylinder fitting ................................................................................................................................................... 14 Nm (10 ft. lbs.) Rear wheel cylinder bolts ............................................................................................ ............................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation Wheel Cylinder Removal and Installation 1. Remove the rear brake drum. 2. Using the Brake/Clutch/Service Vacuum, remove brake dust and dirt from the brake assemblies. 3. Remove the parking brake cable from the parking brake cable lever. 4. Remove the hold-down clips and pins. 5. Remove the lower spring. 6. Remove the rear brake shoes. 1 Pull the bottom of the brake shoe forward. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4862 2 Release the upper return spring. 3 Remove both brake shoes together. 7. WARNING: Use of any other than approved DOT 4 or DOT 3 brake fluid will cause permanent damage to brake components and will render brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. Disconnect the brake line fitting from the wheel cylinder. 8. Remove the wheel cylinder. 1 Remove the bolts. 2 Remove the wheel cylinder. 9. To install, reverse the removal procedure. ^ Bleed the brake hydraulic system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4863 Wheel Cylinder: Service and Repair Disassembly and Assembly Wheel Cylinder Disassembly 1. Remove the rear wheel cylinder. 2. CAUTION: Do not use denatured alcohol for flushing the brake system or cleaning assemblies where alcohol could be trapped. If denatured alcohol is trapped, it can cause eventual failure of rubber components in the system. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic system. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all new rubber seals and flex hoses must be installed. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Disassemble the rear wheel cylinder. 1 Remove the bleeder screw cap. 2 Remove the bleeder screw. 3 Remove the dust boots. 4 Remove the pistons and piston seals. 5 Remove the spring. 3. Inspect the rear wheel cylinder bore for wear, rust or pits. If any of these conditions exist, install a new wheel cylinder. Assembly 1. CAUTION: Always install new piston seals and dust boots when assembling the rear wheel cylinder. Always lubricate the bore with new brake fluid. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. To assemble, reverse the disassembly procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel cylinder bleeder screws ............................................................................................................ .................................................... 8 Nm (71 inch lbs.) Bleeder screws ................................................ ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System Brake Bleeding: Service and Repair Bleeding - System Brake System Bleeding Special Tool(s) Anti-Lock Brakes Bleed NOTE: Bleeding the Hydraulic Control Unit (HCU) is required only when removing or installing the HCU or master cylinder, or opening the lines to the HCU. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the diagnostic tool. 2. Access the SYSTEM BLEED FUNCTION. Go to the Tool Tab-Chassis-Braking-ABS Service Bleed and follow the directions on the diagnostic tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of two diagnostic tool cycles and two manual bleed cycles. Manual Bleed Brake system WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. (let medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system alter it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel then to the RH front wheel and ending with the LH front wheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4870 Rear drum brakes 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 5. Loosen the bleeder screw until fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw. 6. Repeat Steps 4 and 5 until clear, bubble-free brake fluid flows. 7. Tighten the wheel cylinder bleeder screw. 8. Continue bleeding the rest of the system. Front disc brakes 9. Attach a rubber drain hose to the front disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 10. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 11. Loosen the front disc brake caliper bleeder screw until fluid flow stops. Maintain pressure on the brake pedal and tighten the front disc brake caliper bleeder screw. 12. Repeat Steps 10 and 11 until clear, bubble-free fluid flows. 13. Tighten the front disc brake caliper bleeder screw. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4871 14. Fill the brake master cylinder reservoir and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Gravity Bleed Brake system 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel, then to the RH front wheel and ending with the LH front wheel. Rear drum brakes 3. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Loosen the rear wheel cylinder bleeder screw and leave open until clear, bubble-free brake fluid flows. 4. Tighten the wheel cylinder bleeder screw. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4872 Front disc brakes 5. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Open the front disc brake caliper bleeder screw. Leave open until clear bubble-free brake fluid flows. 6. Tighten the front disc brake caliper bleeder screw. 7. Fill the brake master cylinder reservoir with fluid and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Brake System Pressure Bleeding Special Tool(s) WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4873 with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Clean the outside of the brake master cylinder reservoir. 2. Remove the reservoir cap and fill the brake master cylinder reservoir with brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 3. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install Brake Bleeder to the brake master cylinder reservoir, and attach the Brake Bleeder tank hose to the fitting on the adapter. 4. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid. 5. Open the valve on the Brake Bleeder tank. 6. Loosen the bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close the bleeder screw and remove the rubber hose. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4874 7. Tighten the wheel cylinder bleeder screw. 8. Continue bleeding the rest of the system, going in order from the LH rear wheel to the RH front wheel, ending with the LH front wheel. 9. Close the Brake Bleeder tank valve and remove the tank hose from the adapter, and remove the adapter. 10. Fill the brake master cylinder reservoir and install the reservoir cap. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4875 Brake Bleeding: Service and Repair Bleeding - Components Component Bleeding Brake Master Cylinder-Bench Bleed WARNING: Use of any other than the approved DOT 3 brake will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed air may enter the system causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Support the brake master cylinder body in a soft jaw vise 2. Remove the master cylinder cap and install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir 3. NOTE: If equipped with a manual transmission plug the master cylinder feed port Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4876 Fill the brake master cylinder reservoir with High Performance DOT 3 brake fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A DOT 3 4. Slowly depress the primary piston until bubble -free brake fluid flows from both brake hoses 5. Remove the brake hoses from the master cylinder. 6. Install plugs in the front and rear brake outlet port. 7. Install the reservoir cap and install the brake master cylinder in the vehicle. ^ Remove the master cylinder outlet port plugs before installing the lines Brake Master Cylinder-In-Vehicle Bleed WARNING: Use of any other than the approved DOT 3 brake will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. Disconnect the brake outlet lines from the brake master cylinder and cap the lines. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding - System > Page 4877 2. Install short brake hoses to the master cylinder outlet ports with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 4. Have an assistant pump the brake pedal until clear, bubble-free brake fluid flows from both brake hoses. 5. Remove the short brake hoses and install the brake outlet lines. 6. Bleed the hydraulic brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Disc brake caliper bleeder screws ............................................................................................................................................................. 16 Nm (12 ft. lbs.) Front disc brake caliper bore mm (in) .................................................................... .............................................................................................. 60.0 (2.36) Brake caliper anchor plate bolts ........................................................................................................................................................... 150 Nm (111 ft. lbs.) Brake caliper bolts ............................................................................................. ....................................................................................... 35 Nm (26 ft. lbs.) Brake line to caliper ....... .............................................................................................................................................................. ............. 20 Nm (15 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation Brake Caliper: Service and Repair Caliper Removal and Installation Brake Caliper Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. 1. Remove the wheel and tire assembly. 2. Remove the brake caliper clip 3. Position the caliper aside 1 Remove the brake caliper bolt caps and bolts 2 Position the caliper aside 4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4883 with water. NOTE: When any part of the hydraulic system has been disconnected for repair or a new component has been installed, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with a Brake Bleeder. Disconnect and cap the brake line from the caliper and remove the caliper. 5. CAUTION: Do no use denatured alcohol for flushing the brake system or cleaning assemblies where alcohol could be trapped. If denatured alcohol is trapped, it can cause eventual failure of rubber components in the system. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic systems. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all rubber seals and flex hoses replaced. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4884 Brake Caliper: Service and Repair Caliper Disassembly and Assembly Brake Caliper Disassembly 1. Remove front disc brake caliper from the vehicle. 2. Remove the front caliper slide pins and boots. 3. Remove the dust seal. 4. WARNING: Use only as much compressed air as necessary to remove the piston. Excessive pressure can force the piston out of the caliper bore with enough force to cause personal injury. Never attempt to catch the piston by hand as it comes out of the bore. Failure to follow these instructions may result in personal injury. CAUTION: Do not use a screwdriver or any other similar tool to pry the piston out of the bore. Piston damage could result. NOTE: Inspect the piston for wear, rust, or pits. If any of these conditions exist, a new piston must be installed. Remove the caliper piston. 1 Position a block of wood between the piston and the disc brake caliper. 2 Apply compressed air to caliper to remove piston. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4885 5. Remove the bleeder screw. 6. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak. NOTE: Inspect the caliper bore for wear, rust or pits If any of these conditions exist, do not hone; a new caliper must be installed Remove the piston seal. Assembly CAUTION: Do not use denatured alcohol to clean rubber components or assemblies that have rubber components. Cleaning rubber components with denatured alcohol weakens the rubber and may result in failure of the component. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic system. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all rubber seals and flex hoses replaced. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. NOTE: Be sure the seal is not twisted and is firmly seated in the caliper bore NOTE: Clean all brake caliper components. All parts must be air-dried completely Coat all internal parts and piston seal with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A. DOT 3 before installation. To assemble, reverse the disassembly procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation > Page 4886 Brake Caliper: Service and Repair Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal and Installation 1. Remove the wheel and tire assembly. 2. Remove the brake caliper clip. 3. Position the caliper aside. 1 Remove the brake caliper bolt caps and the bolts. 2 Position the caliper aside and support. 4. Remove the outboard brake pad. 5. Remove the bolts and brake caliper anchor plate. 6. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the line on the reservoir. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 4891 Brake Fluid: Fluid Type Specifications Fluid Type ......................................................................................................................................... High Performance DOT 3 Motor Vehicle Brake Fluid Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4895 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4896 Brake Fluid Level Sensor/Switch: Description and Operation Brake Fluid Level Warning Switch The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the float and magnet actuates the reed switch that causes the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake line fitting to brake pressure control valve fittings ......................................................................................................................... 14 Nm (10 ft. lbs.) Brake line master cylinder fittings ............................................................................................................................................................ 15 Nm (11 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 4900 Brake Hose/Line: Description and Operation Brake Lines and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which could result in brake tube failure. Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong leakproof connections. If a section of brake tube is damaged, the entire section must be removed and a new tube of the same type, size, shape and length installed. When installing new hydraulic brake lines, hoses, or connectors, tighten all connections securely. After installation, bleed the brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Brake pressure control valve bolts .......................................................................................................................................................... 9 Nm (80 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4904 Brake Proportioning/Combination Valve: Description and Operation Brake Pressure Control Valve The brake pressure control valve proportions the pressure to the rear brakes. ^ When the brake pedal is applied, brake fluid pressure passes through the brake pressure control valve to the rear brake system until the valve split point is reached. ^ Above its split point, the brake pressure control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear brakes. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4905 Brake Proportioning/Combination Valve: Service and Repair Brake Pressure Control Valve Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the brake pressure control valve. 1 Disconnect the six brake line fittings and plug the brake lines. 2 Remove the brake pressure control valve bolts 2. To install reverse the removal procedure ^ Bleed the brake system Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Control module bolts1 .......................................................................................................................... ............................................ 1-2 Nm (9-17 inch lbs.) Hydraulic control unit (HCU) to bracket bolts ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4909 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery negative cable. 2. Remove the air cleaner and the air cleaner outlet pipe. 3. Disconnect the electrical connector 4. Disconnect the brake lines. 5. Remove the bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 4910 6. Remove the bolts and the HCU. 7. NOTE: The 4x2 module cannot be interchanged with the 4x4 module. The 4x4 module is interchangeable with the 4x2 module. Remove the screws and the control module, if necessary. 8. NOTE: Bleed the HCU after performing this procedure. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Brake line master cylinder fittings ........................................................................................................................................................... 15 Nm (11 ft. lbs.) Brake master cylinder ............................................................................................ ................................................................................... 25 Nm (18 ft. lbs.) Master cylinder nuts ........... .............................................................................................................................................................. ........ 17 Nm (13 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder Brake Master Cylinder: Description and Operation Brake Master Cylinder Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder operates as follows: ^ When the brake pedal is depressed, pressure is applied by mechanical linkage to the primary and secondary piston. ^ Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits. The brake master cylinder consists of the following components: ^ brake master cylinder reservoir ^ brake master cylinder body ^ primary piston ^ secondary piston ^ snap ring Whenever the brake master cylinder is removed from the brake booster, new nuts must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder > Page 4916 Brake Master Cylinder: Description and Operation Brake Fluid Reservoir Brake Master Cylinder Reservoir NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder, new seals must be installed. The brake master cylinder reservoir: ^ is mounted to the brake master cylinder. ^ holds fluid supply for each brake master cylinder hydraulic piston. ^ provides visual fluid level markings. ^ contains the brake master cylinder fluid level warning switch. On vehicles equipped with a manual transmission, the reservoir is shared with the clutch master cylinder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the brake fluid level warning switch electrical connector 2. Using a suitable suction device drain the brake master cylinder reservoir 3. If equipped with manual transmission, disconnect the clutch master cylinder feed. 4. Disconnect the brake lines and plug the lines and the brake master cylinder ports. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4919 5. NOTE: Whenever the brake master cylinder is removed from the brake booster, new nuts must be installed. Remove the nuts and the brake master cylinder. 6. NOTE: Whenever installing a new brake master cylinder reservoir, install new seals. Lubricate the new seals with clean brake fluid. Transfer the brake master cylinder reservoir if a new master cylinder is to be installed. 1 Lubricate the two O-ring seals with clean brake fluid and insert into the brake master cylinder. 2 Press the brake master cylinder reservoir into the O-ring seals until it snaps into the brake master cylinder securely. 7. To install, reverse the removal procedure. ^ Bleed the master cylinder. ^ If equipped with manual transmission, bleed the clutch master cylinder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4920 Brake Master Cylinder: Service and Repair Disassembly and Assembly Disassembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the brake master cylinder. 2. Clean the outside of the brake master cylinder. 3. Remove the brake master cylinder reservoir. 4. Remove the seals. 5. Remove the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4921 6. Remove the primary and secondary piston. 7. NOTE: If the brake master cylinder bore is damaged a new brake master cylinder must be installed. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. Assembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Use clean brake fluid to lubricate the new piston assembly seals and the brake master cylinder bore. 2. Install the secondary piston assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4922 3. Install the primary piston assembly 4. Install the snap ring. 5. Install the seals ^ Lubricate the seals with clean brake fluid and insert the seals into the brake master cylinder. 6. Install the brake master cylinder reservoir. ^ Press the brake master cylinder reservoir into the seals until it snaps in securely. 7. Install master cylinder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4923 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the fluid level electrical connector. 2. Using a suitable suction device, drain the brake master cylinder reservoir. 3. If equipped with manual transmission, disconnect the clutch master cylinder feed. 4. Remove the brake master cylinder reservoir. Installation NOTE: Whenever installing a new brake master cylinder reservoir, install new seals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4924 1. Install the new brake master cylinder reservoir. 1 Lubricate the two seals with clean brake fluid and insert the seals into the brake master cylinder. 2 Press the brake master cylinder reservoir into the seals until it snaps in securely. 3 Connect the brake master cylinder fluid level warning switch electrical connector. 2. If equipped with manual transmission, connect the clutch master cylinder feed. ^ Bleed the clutch master cylinder. 3. Bleed the master cylinder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel cylinder inner diameter mm (in) ............................................................................................................................................................ 23.81 (0.937) Brake line to rear wheel cylinder fitting ................................................................................................................................................... 14 Nm (10 ft. lbs.) Rear wheel cylinder bolts ............................................................................................ ............................................................................... 12 Nm (9 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation Wheel Cylinder Removal and Installation 1. Remove the rear brake drum. 2. Using the Brake/Clutch/Service Vacuum, remove brake dust and dirt from the brake assemblies. 3. Remove the parking brake cable from the parking brake cable lever. 4. Remove the hold-down clips and pins. 5. Remove the lower spring. 6. Remove the rear brake shoes. 1 Pull the bottom of the brake shoe forward. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4930 2 Release the upper return spring. 3 Remove both brake shoes together. 7. WARNING: Use of any other than approved DOT 4 or DOT 3 brake fluid will cause permanent damage to brake components and will render brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. 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: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. Disconnect the brake line fitting from the wheel cylinder. 8. Remove the wheel cylinder. 1 Remove the bolts. 2 Remove the wheel cylinder. 9. To install, reverse the removal procedure. ^ Bleed the brake hydraulic system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 4931 Wheel Cylinder: Service and Repair Disassembly and Assembly Wheel Cylinder Disassembly 1. Remove the rear wheel cylinder. 2. CAUTION: Do not use denatured alcohol for flushing the brake system or cleaning assemblies where alcohol could be trapped. If denatured alcohol is trapped, it can cause eventual failure of rubber components in the system. CAUTION: Never allow any petroleum product or mineral oil to contact the inside of a brake hydraulic system. Mineral oil and petroleum products deteriorate the natural rubber seals used in brake hydraulic system. If a brake system becomes contaminated, it must be flushed with clean brake fluid and all new rubber seals and flex hoses must be installed. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Disassemble the rear wheel cylinder. 1 Remove the bleeder screw cap. 2 Remove the bleeder screw. 3 Remove the dust boots. 4 Remove the pistons and piston seals. 5 Remove the spring. 3. Inspect the rear wheel cylinder bore for wear, rust or pits. If any of these conditions exist, install a new wheel cylinder. Assembly 1. CAUTION: Always install new piston seals and dust boots when assembling the rear wheel cylinder. Always lubricate the bore with new brake fluid. Use High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT 3. To assemble, reverse the disassembly procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Parking brake cable bracket bolt ......................................................................................................... ...................................................... 22 Nm (16 ft. lbs.) Parking brake cable equalizer bracket bolt .............................................................................................................................................. 9 Nm (80 inch lbs.) Rear parking brake cable bracket bolts ..................................................................................................................................................... 23 Nm (17 ft. lbs.) Rear parking brake cable to knuckle bracket bolts ................................................................................................................................... 23 Nm (17 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 4936 Parking Brake Cable: Adjustments Parking Brake Cable Adjustment Vehicle with low series floor console 1. Remove the floor console front finish panel. 1 If equipped, remove the manual transmission shift knob by turning counterclockwise. 2 Remove the floor console front finish panel. 2. Remove the floor console rear finish panel. 1 Apply the parking brake. 2 Remove the floor console rear finish panel. Vehicle with high series floor console 3. Remove the floor console finish panel. 1 Apply the parking brake. 2 Remove the floor console finish panel. All vehicles 4. Remove the adjustment nut clip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 4937 5. Turn the parking brake control adjustment nut so that the parking brake control stroke is three to five notches when pulled. 6. Confirm the parking brake is applied. 7. Install the adjustment nut clip. Vehicle with high series floor console 8. Install the floor console rear finish panel. Vehicle with low series floor console 9. Install the floor console rear finish panel. 10. Install the floor console front finish panel. ^ If equipped, install the manual transmission shifter knob by turning clockwise. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front Parking Brake Cable: Service and Repair Parking Brake Cable - Front Removal and Installation All Vehicles 1. Remove the parking brake control. With Floor Console 2. Remove the two bolts and the floor console bracket. Without Floor Console 3. Remove the LH front seat. 4. Remove the LH front door scuff plate. 5. Remove the LH lower A-pillar trim panel. 6. Remove the LH front safety belt. 7. Pull back carpet to gain access to the console bracket. 8. Remove the two bolts and the floor console bracket. All Vehicles 9. Raise and support the vehicle. 10. Remove the front parking brake cable. 1 Disconnect the parking brake cable from the RH side rear parking brake cable. 2 Disconnect the front parking brake cable from the parking brake cable equalizer. 11. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 4940 Parking Brake Cable: Service and Repair Parking Brake Cable - Rear Removal and Installation All vehicles 1. Remove the rear drum brake shoes. ABS-equipped vehicles 2. Remove the ABS cable bracket bolt. All vehicles 3. Remove the rear parking brake cable to trailing arm bracket bolts. 4. Disconnect the rear parking brake cable from the backing plates. 5. Remove the rear parking brake cable bracket bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 4941 6. Remove the RH side rear parking brake cable. 1 Disconnect the RH side rear parking brake cable from the front parking brake cable. 2 Disconnect the RH side rear parking brake cable from the body-mounted parking brake cable support bracket. 7. Disconnect the LH rear parking brake cable to fuel tank support strap. 8. Disconnect the front parking brake cable. 9. Remove the LH rear parking brake cable. 1 Remove the two bolts. 2 Disconnect the LH rear parking brake cable from the body-mounted parking brake cable support bracket. 10. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Parking brake control bolts .................................................................................................................. ..................................................... 24 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 4945 Parking Brake Control: Service and Repair Parking Brake Control Removal and Installation 1. Remove the floor console. 2. Release the parking brake control. 3. Disconnect the parking brake warning indicator switch electrical connector. 4. Remove the parking brake adjusting nut. 5. Remove the parking brake control. 1 Remove the bolts. 2 Remove the parking brake cable. 6. To install, reverse the removal procedure. ^ Adjust the parking brake cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4949 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4950 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake warning indicator switch. ^ Remove the screws. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4955 Vacuum Brake Booster: Description and Operation Brake Booster The brake booster consists of the following components: ^ power brake booster ^ vacuum booster hose ^ power brake booster check valve The power brake booster reduces the effort required to push the brake pedal to actuate the brakes The vacuum booster hose supplies vacuum to the brake booster. The vacuum booster check valve closes when the engine is turned off and traps engine vacuum in the power brake booster. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4956 Vacuum Brake Booster: Testing and Inspection Brake Booster-Operation Check 1. Inspect all vacuum hoses and connections. All unused vacuum connectors must be capped Hoses and their connections must be correctly secured and in good condition with no holes, cracks, or collapsed areas. 2. Check the brake hydraulic system for leaks or insufficient brake fluid. Repair as necessary. 3. With the engine off, place the transaxle in PARK (A/T) or NEUTRAL (M/T) and apply the parking brake. 4. NOTE: If the power brake booster is noisy when the brakes are applied, a new component must be installed. Press the brake pedal several times to exhaust all of the vacuum from the system. 5. Press and hold the brake pedal. 6. Start the engine. If the vacuum system is operating, the brake pedal will move downward under constant foot pressure. If no movement occurs, the power brake booster system is not functioning. 7. Remove the vacuum booster hose from the power brake booster. 8. Place the transaxle in PARK (A/T) or NEUTRAL (M/T) and apply the parking brake. Start the engine. Manifold vacuum should be available from the vacuum booster hose. If manifold vacuum is not available, inspect all of the hoses and hose connections. Repair as necessary. 9. Reconnect the vacuum booster hose and run the engine at fast idle for 10 seconds. 10. Stop the engine and let the vehicle stand for 10 minutes. 11. Apply the brake pedal with approximately 89 Nm (20 ft. lbs.) of force. The brake pedal feel should be the same as normal power assisted brake operation for at least one application. If the brake pedal feel is normal, then the power brake booster is OK. If the brake pedal feels hard, continue with the test. 12. Remove the vacuum booster hose from the power brake booster. Apply 57.3 kPa (17 in-Hg) of vacuum to the vacuum booster hose. If the vacuum does not leak off after l0 minutes, install a new power brake booster. If the Vacuum does leak off. install a new check valve and/or new vacuum booster hose. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4957 Vacuum Brake Booster: Service and Repair Removal and Installation All vehicles 1. Remove the brake pedal push rod cotter pin and washer. 2. Remove the four power brake booster pushrod bracket nuts. 3. Disconnect the brake pedal pushrod. 3.0 L (4V) 4. Disconnect the Evaporative Emission Canister Purge Valve and position it aside. 1 Disconnect the cable locator. 2 Remove the nuts. 3 Position the evaporative emission canister purge valve aside. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4958 All vehicles 5. Disconnect the master cylinder and position aside. ^ Remove the nuts ^ Position the master cylinder aside. 6. Remove the brake booster. 1 Disconnect the vacuum hose. 2 Remove the brake booster. 7. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve 1. Remove the vacuum booster hose from the power brake booster. 2. APPLY 57.3 kPa (17 in-Hg) of vacuum to the vacuum booster hose. If the vacuum does not leak off after ten minutes. the check valve is OK. Otherwise, install a new check valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair Technical Service Bulletin # 07S51S2 Date: 091009 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4971 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated April 10, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website. Owner names and addresses were made available April 30, 2007. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4972 NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles have been directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 07S51 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES If an ABS module needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Handling Allowance: An allowance of $1.00 per repair is being provided to cover the costs of locally obtained materials and XG-12 Electrical Grease. To claim the allowance, enter $1.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4973 ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4974 Parts will not be direct shipped for this program Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50376. Questions regarding parts should be directed to the Special Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected ABS Modules (Part number YL8Z-2C065-AA and YL8Z-2B373-BA) and the removed ABS connector are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector. During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number. If the ABS module is corroded, the ABS module and connector must be replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4975 A flow chart has been developed to help direct you to the proper repair. See Figure 1. Inspect Connector Seals INSPECTION 1. Disconnect the battery negative terminal. 2. NOTE: When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed. Disconnect the ABS module 25-pin connector by sliding the lock mechanism out (towards the passenger side of the vehicle) and pulling the connector off the module. 3. Disconnect the speed sensor harness, then remove the 2 harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection. 4. Inspect the top of the ABS module connector cover for 2 yellow "X" marks. ^ If 2 yellow "X" marks are present, perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. ^ If no yellow "X" marks are present, proceed to Step 5. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4976 5. Inspect the ABS module connector pins for corrosion. See Figure 2. ^ If corrosion is present, perform Labor Operation E - Install Pigtail, New ABS Module and Apply Electrical Grease. ^ If corrosion is not present, proceed to Step 6. 6. CAUTION: Do not cut any of the harness wires or the wire insulation when cutting off the tie strap. Remove the tie strap from the connector dress cover, then slide the cover off the connector. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4977 7. Verify the wire seals are present on the 4 heavier gauge wires. See Figure 4. 8. Verify the numbers 054" are stamped on the slide-lock end of the mat cover (wipe the mat cover clean if necessary to view). See Figure 5. NOTE: Mat covers with any other number will be missing plugs in the unused pin locations. 9. Perform Labor Operation C - Install Pigtail and Apply Electrical Grease if: ^ any seals are missing or, ^ if the number on the mat cover is not "054". 10. Perform Labor Operation D - Seat Connector and Apply Electrical Grease if: ^ Any of the 4 wire seals are not fully seated in the connector cavities. ^ Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. See Figure 4. 11. Perform Labor Operation A - Apply Electrical Grease if: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4978 ^ The module is not corroded. and ^ All seals are present. and ^ All seals are fully seated. and ^ The number on the mat cover is "054". LABOR OPERATION A - APPLY ELECTRICAL GREASE 1. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 6. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 6. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 3. Reconnect the battery negative terminal. LABOR OPERATION C - INSTALL PIGTAIL AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4979 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 7. 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 8. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 8. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4980 3. Strip approximately 6 mm (1/2 in) of insulation from each of the cut wires in the harness. See Figure 9. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4981 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 10. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 11. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4982 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 12. 8. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 13. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4983 connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 13. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 9. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 10. Reconnect the battery negative terminal. 11. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION D - SEAT CONNECTOR SEALS AND APPLY ELECTRICAL GREASE 1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool. DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal. See Figure 14. 2. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4984 b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 15. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 15. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 4. Reconnect the battery negative terminal. LABOR OPERATION E - INSTALL PIGTAIL, NEW ABS MODULE AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4985 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 16. PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 17. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 17. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4986 3. Strip approximately 6 mm (1/4 in) of insulation from each of the cut wires in the harness. See Figure 18. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4987 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 19. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 20. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4988 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 21. 8. Install a new ABS module. Perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. 9. Reconnect the battery negative terminal. 10. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION F - INSTALL NEW ABS MODULE AND APPLY ELECTRICAL GREASE NOTE: Module configuration or reprogramming is not required when installing a new ABS module. 1. Disconnect the 2-wire electrical connector at the ABS module. 2. Raise the vehicle on a hoist. 3. Remove the screws and the ABS module. 4. Position the new module and install the screws. Tighten the screws no more than 2 Nm (18 lb-in). 5. Lower the hoist. 6. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4989 ^ Use ONLY Motorcraft Electrical Grease XG-12. See Figure 22. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 22. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 7. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 8. Reconnect the 2-wire connector to the ABS module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4990 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4991 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4992 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4993 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4994 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 4995 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA07V156000 > Mar > 07 > Recall 07V156000: ABS Module Connector Defect Electronic Brake Control Module: Recalls Recall 07V156000: ABS Module Connector Defect MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V156000 MFR'S REPORT DATE: March 30, 2007 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 446460 SUMMARY: On certain sport utility vehicles equipped with Antilock Brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short. CONSEQUENCE: An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated. Remedy: Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on April 23, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S51. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair Technical Service Bulletin # 07S51S2 Date: 091009 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5005 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated April 10, 2007. FSA VIN LIST ACTIVATED? Yes. Available through the website. Owner names and addresses were made available April 30, 2007. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5006 NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles have been directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 07S51 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES If an ABS module needs to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Handling Allowance: An allowance of $1.00 per repair is being provided to cover the costs of locally obtained materials and XG-12 Electrical Grease. To claim the allowance, enter $1.00 as "HANDLG" in the "MISC EXPENSE" area of the claim form. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5007 ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5008 Parts will not be direct shipped for this program Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50376. Questions regarding parts should be directed to the Special Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected ABS Modules (Part number YL8Z-2C065-AA and YL8Z-2B373-BA) and the removed ABS connector are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector. During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number. If the ABS module is corroded, the ABS module and connector must be replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5009 A flow chart has been developed to help direct you to the proper repair. See Figure 1. Inspect Connector Seals INSPECTION 1. Disconnect the battery negative terminal. 2. NOTE: When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed. Disconnect the ABS module 25-pin connector by sliding the lock mechanism out (towards the passenger side of the vehicle) and pulling the connector off the module. 3. Disconnect the speed sensor harness, then remove the 2 harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection. 4. Inspect the top of the ABS module connector cover for 2 yellow "X" marks. ^ If 2 yellow "X" marks are present, perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. ^ If no yellow "X" marks are present, proceed to Step 5. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5010 5. Inspect the ABS module connector pins for corrosion. See Figure 2. ^ If corrosion is present, perform Labor Operation E - Install Pigtail, New ABS Module and Apply Electrical Grease. ^ If corrosion is not present, proceed to Step 6. 6. CAUTION: Do not cut any of the harness wires or the wire insulation when cutting off the tie strap. Remove the tie strap from the connector dress cover, then slide the cover off the connector. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5011 7. Verify the wire seals are present on the 4 heavier gauge wires. See Figure 4. 8. Verify the numbers 054" are stamped on the slide-lock end of the mat cover (wipe the mat cover clean if necessary to view). See Figure 5. NOTE: Mat covers with any other number will be missing plugs in the unused pin locations. 9. Perform Labor Operation C - Install Pigtail and Apply Electrical Grease if: ^ any seals are missing or, ^ if the number on the mat cover is not "054". 10. Perform Labor Operation D - Seat Connector and Apply Electrical Grease if: ^ Any of the 4 wire seals are not fully seated in the connector cavities. ^ Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. See Figure 4. 11. Perform Labor Operation A - Apply Electrical Grease if: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5012 ^ The module is not corroded. and ^ All seals are present. and ^ All seals are fully seated. and ^ The number on the mat cover is "054". LABOR OPERATION A - APPLY ELECTRICAL GREASE 1. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 6. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 6. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 3. Reconnect the battery negative terminal. LABOR OPERATION C - INSTALL PIGTAIL AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5013 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 7. 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 8. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 8. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5014 3. Strip approximately 6 mm (1/2 in) of insulation from each of the cut wires in the harness. See Figure 9. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5015 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 10. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 11. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5016 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 12. 8. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 13. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5017 connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 13. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 9. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 10. Reconnect the battery negative terminal. 11. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION D - SEAT CONNECTOR SEALS AND APPLY ELECTRICAL GREASE 1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool. DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal. See Figure 14. 2. Reinstall the dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply Motorcraft Electrical Grease XG-12 to the ABS module connector, position and connect the harness as follows: a) Reinstall the dress cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5018 b) Use ONLY Motorcraft Electrical Grease XG-12. See Figure 15. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 15. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 4. Reconnect the battery negative terminal. LABOR OPERATION E - INSTALL PIGTAIL, NEW ABS MODULE AND APPLY ELECTRICAL GREASE IMPORTANT SERVICE INFORMATION When performing the service pigtail installation, it is critical that the crimp tool and the flameless heat gun found in the Rotunda Wire Splice Tool Kit / 64-R5903 be used. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5019 USING DIFFERENT TOOLS MAY RESULT IN A POOR QUALITY REPAIR. See Figure 16. PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR 1. Remove the tape and the convolute from the vehicle harness which leads up to the ABS module connector. See Figure 17. 2. Measure approximately 75 mm (3 in) from the end of the elbow towards the ABS module connector, then, using suitable wire cutters, cut the harness (all wires) to the same length. See Figure 17. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5020 3. Strip approximately 6 mm (1/4 in) of insulation from each of the cut wires in the harness. See Figure 18. CAUTION: The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag. Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when, in fact, all wires in the ABS module harness are different except for the 2 black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires. NOTE: The harness contains 2 black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation. NOTE: The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness and a piece of heat shrink tubing to cover each splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5021 4. Working with one wire at a time, match the wires from the service pigtail to the vehicle harness. Insert the stripped end of each wire into the splice connector and crimp using the crimp tool provided in the Rotunda Wire Splice Tool Kit 164-R5903. See Figure 19. 5. Using rosin core solder, solder only the vehicle harness side of the wires to the butt splice connector. 6. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using the flameless heat gun provided in the Rotunda Kit, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated. See Figure 20. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5022 7. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other. See Figure 21. 8. Install a new ABS module. Perform Labor Operation F - Install New ABS Module and Apply Electrical Grease. 9. Reconnect the battery negative terminal. 10. Turn the ignition key to the RUN position. Allow the ABS to carry out a self-test (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately 3 seconds). ^ If the yellow ABS indicator is not illuminated after 3 seconds, release the vehicle. ^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Special Support Service Center. LABOR OPERATION F - INSTALL NEW ABS MODULE AND APPLY ELECTRICAL GREASE NOTE: Module configuration or reprogramming is not required when installing a new ABS module. 1. Disconnect the 2-wire electrical connector at the ABS module. 2. Raise the vehicle on a hoist. 3. Remove the screws and the ABS module. 4. Position the new module and install the screws. Tighten the screws no more than 2 Nm (18 lb-in). 5. Lower the hoist. 6. Apply Motorcraft Electrical Grease XG-1 2 to the ABS module connector, position and connect the harness as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5023 ^ Use ONLY Motorcraft Electrical Grease XG-12. See Figure 22. - With the tip of the applicator tube snipped off, position the end of the tip between the 4 large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the 4 flat pins. See Figure 22. DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a hydro lock" condition in which the connector will not be able to be seated fully or locked in place. 7. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module. 8. Reconnect the 2-wire connector to the ABS module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5024 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5025 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5026 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5027 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5028 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 07S51S2 > Oct > 09 > Recall - ABS Module Connector Inspection/Repair > Page 5029 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA07V156000 > Mar > 07 > Recall 07V156000: ABS Module Connector Defect Electronic Brake Control Module: All Technical Service Bulletins Recall 07V156000: ABS Module Connector Defect MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V156000 MFR'S REPORT DATE: March 30, 2007 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 446460 SUMMARY: On certain sport utility vehicles equipped with Antilock Brakes (ABS), the ABS module connector may have missing or dislodged wire seals. This condition could allow contamination to enter the module connector, creating a potential for an electrical short. CONSEQUENCE: An electrical short might cause an ABS malfunction that would illuminate the ABS warning light, and in some cases, the module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated. Remedy: Dealers will inspect the wire harness connector to the ABS module for missing or dislodged wire seals, and repair or replace the harness connector as appropriate. The dealer will also inspect the connector on the ABS module and replace it if it is found to be corroded or damaged. The recall began on April 23, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S51. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5034 View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5035 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5036 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery negative cable. 2. Disconnect the electrical connectors. 3. Raise and support the vehicle. 4. Remove the screws and the control module. 5. NOTE: The 4x2 module cannot be interchanged with the 4x4 module. The 4x4 module is interchangeable with the 4x2 module. To install. reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5041 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5042 Brake Fluid Level Sensor/Switch: Description and Operation Brake Fluid Level Warning Switch The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the float and magnet actuates the reed switch that causes the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5046 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5047 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake warning indicator switch. ^ Remove the screws. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Removal Tips Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Removal Tips TSB 04-23-2 11/29/04 WHEEL SPEED SENSOR REMOVAL TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE When servicing the wheel speed sensors on a 2001-2005 Escape or 2005 Mariner and Escape Hybrid, care must be taken during removal to prevent damage. The wheel speed sensor wire has a body plug attached to it. This plug can be damaged if not removed correctly, such as removal for pinpoint testing. If the body plug is damaged, sensor replacement may be necessary even though the sensor is functional in all other respects. ACTION When removing the body plug, rotate the plug into a position which allows the use of a small screwdriver to release the tabs on the underside of the body plug. These two tabs are at right angles (directly above and below) to the sensor wire. See Figures 1 and 2 for reference. WARRANTY STATUS: Information Only Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Removal Tips > Page 5052 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front View 151-14 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5055 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5056 View 151-27 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 5057 View 151-28 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5060 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5061 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5062 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 5063 Wheel Speed Sensor: Service and Repair Sensor-Front Removal and Installation 1. Remove the wheel and tire. 2. Detach the grommet from the body and pull the connector through the hole. 3. Disconnect the sensor wiring. 4. Detach the retainer. 5. Remove the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 5064 6. NOTE: Clean off any dirt that may have collected around the sensor before removal. Remove the bolt and the sensor. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Clutch Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Clutch Switch > Page 5071 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 5074 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL 1. Disconnect the battery ground cable. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5082 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5087 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay Starter Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 5090 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 5091 Starter Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 5092 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair REMOVAL 1. Remove the battery tray. 2. Remove the air cleaner assembly. 3. Remove the fuse junction box cover. 4. Remove the cables. 1 Remove the nuts and the cable. 2 Release the lock clip and pull down on the connector. 5. Remove the bolt from the inner fender. 6. Remove the bolt holding the ground cable to the transaxle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 5097 7. Disconnect the harness clip. 8. Disconnect the harness Clip at the back of the engine. 9. Remove the cable clip from under the battery support. 10. Raise and support the vehicle. Refer to Maintenance/Service and Repair. 11. Remove the cable ends from the starter solenoid. 1 Remove the upper nut. 2 Remove the lower nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 5098 12. Remove the nut and the cable end from the generator B+ connector. 13. Remove the battery cable harness assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Output Amps ........................................................................................................................................ ................................................................. 110 Amps Generator ......................................................... .......................................................................................................................................................... 95 amp Generator Output .................................................................................................................... ................................................................... At Least 58 amps voltage (Running At 2,000 RPM) ........ ....................................................................................................................................................... 13.0 - 15.0 volts Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 5104 Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views Alternator: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views > Page 5107 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5108 Alternator: Service Precautions CAUTION: ^ To prevent damage to the generator, do not make the jumper wire connections except as directed. ^ Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5109 Alternator: Description and Operation The charging system consists of the following components: ^ generator ^ integral voltage regulator The generator maximum output provides 110 amps. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Generator Testing Alternator: Testing and Inspection Generator Testing CAUTION: ^ To prevent damage to the generator, do not make the jumper wire connections except as directed. ^ Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes. NOTE: ^ Battery posts and cable clamps must be clean and tight for accurate meter indications. ^ Refer to the battery tester manual for complete directions for testing the charging system. 1. Turn off all lamps and electrical components. 2. Place the transmission range selector lever in NEUTRAL and apply the parking brake. 3. Carry out the Load Test and No-Load Test according to the following component tests: Generator On-Vehicle Tests-Load Test 1. Switch the battery tester to the ammeter function. 2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals. 3. Connect the current probe to the generator B+ output terminal, circuit 36 (YE/WH). 4. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam. 5. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. ^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. ^ If the voltage increases as specified, the charging system is operating normally. 6. Adjust the tester load bank to determine the output of the generator. Generator output should be at least 58 amps. Generator On-Vehicle Tests-No Load Test 1. Switch the battery tester to the voltmeter function. 2. Connect the voltmeter positive lead to the generator B+ output terminal, circuit 36 (YE/WH) and the negative lead to ground. 3. Turn all electrical accessories off. 4. With the engine running at 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts. If not, refer back to the pinpoint test or the Symptom Chart. See: Testing and Inspection/Pinpoint Tests See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Generator Testing > Page 5112 Alternator: Testing and Inspection Other Diagnosis and Testing For further information regarding the diagnosis of this component, please refer to Charging System; Testing and Inspection. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Page 5113 Alternator: Service and Repair REMOVAL 1. Disconnect the battery cables. 2. Remove the drive belt. 3. Lower the vehicle. 4. Disconnect the electrical connectors. 1 Remove the nut and disconnect the B+ cable. 2 Remove the connector. 5. Remove the lower generator bolts. 6. Loosen the upper generator bolt from the engine but do not remove it from the generator. NOTE: Insufficient clearance does not allow the bolt to be completely removed. 7. Move the generator to the rear of the vehicle, then lift up and out of the engine compartment. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Before reassembling, place the upper bolt into the generator. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Clutch Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Clutch Switch > Page 5119 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams > Clutch Cutoff Switch > Page 5122 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL 1. Disconnect the battery ground cable. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5130 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection Starter Drive/Bendix: Testing and Inspection Starter Drive and Flywheel Ring Gear Inspection 1. Remove the starter motor. 2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern is normal, install the starter motor. 3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged, install a new starter motor. If necessary, install a new flywheel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5138 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay Starter Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 5141 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 5142 Starter Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 5143 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5149 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5160 Fuse: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5161 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5164 Fuse: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5165 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5170 Fuse Block: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5171 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5174 Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5175 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5176 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5177 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5180 Fuse Block: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5181 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REMOVAL 1. Disconnect the battery cables. 2. NOTE: The 2.0L is shown, the 3.0L is similar. Remove the ground strap. 1 Remove the nut. 2 Remove the bolt. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5188 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5192 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set Multiple Junction Connector: Customer Interest Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set TSB 06-9-3 05/15/06 PCM FAILURE - ELECTRICAL ACCESSORIES INTERMITTENT - INOPERATIVE FORD: 2001-2004 Escape ISSUE Some vehicles may exhibit a powertrain control module (PCM) concern that results in no crank, no start, or malfunction indicator lamp (MIL) with one or more diagnostic trouble codes (DTCs) present. There may also be intermittent or inoperative power windows, door locks, keyless entry system, lighting, speed control, radio, instrument cluster warning lamps (possibly dimly illuminated instead of being off), or other electrical accessories. The concern is typically more noticeable in wet and/or cold weather conditions. This may be the result of connector terminal corrosion in C134, C263, or the central junction box (CJB) which results in either high resistance between the male and female terminals or a short between two or more circuits due to bridging through any corrosion that may be present. Corrosion in C134 may be the result of improper positioning/sealing of C134. Corrosion in C263 or the CJB may be due to a water leak in the left hand A-Pillar area. ACTION Follow the Service Procedure to inspect and repair the connector terminals for evidence of corrosion. Repair any sources of water entry. If no signs of corrosion or water entry are found, follow normal diagnostics. SERVICE PROCEDURE NOTE WHEN DIAGNOSING THE CAUSE OF A PCM FAILURE IT IS CRITICAL THAT THIS INSPECTION AND REPAIR PROCEDURE BE COMPLETED IN ITS ENTIRETY BEFORE INSTALLING A REPLACEMENT SERVICE PART. THE POSSIBILITY EXISTS FOR A 12 VOLT SHORT TO THE 5 VOLT VREF (CIRCUIT). INSTALLATION OF A SERVICE REPLACEMENT PCM WITHOUT ELIMINATING THE 12 VOLT SHORT WILL RESULT IN REPEAT PCM FAILURE. Inspect and repair the following connectors: C134 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5201 1. Open the hood and locate C134 (Figure 1). 2. Disconnect the connector halves and thoroughly inspect the terminals. Clean any corrosion that may be present and replace any damaged terminals. 3. Use shop air to blow out any moisture that may be present in the terminals, then apply dielectric grease to the terminals in both halves of the connector. 4. Reconnect the connector halves and close the hood. C263 1. Open the drivers door and remove the lower kick panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5202 2. Locate C263 as shown in Figure 2. 3. Disconnect the connector halves. 4. Pry out the terminal retainer as shown in Figure 3 and thoroughly inspect the terminals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5203 NOTE THE CORROSION WILL NOT BE VISIBLE UNLESS THE TERMINAL RETAINER IS REMOVED. 5. Clean any corrosion that may be present and replace any damaged terminals. 6. Work dielectric grease into the side opening in the connector, then reinstall the terminal retainer. 7. Apply dielectric grease to the terminals in both halves of the connector. 8. Reconnect the connector halves. CJB (Central Junction Box) 1. Locate the CJB (Figure 2). 2. Disconnect the four harness connectors from the front and the two connectors from the rear of the CJB, and remove the CJB. 3. Inspect the terminals and also the back side of the CJB or evidence of water damage or corrosion. 4. Clean any corrosion that may be present and replace any damaged terminals or components. 5. Apply dielectric grease to the terminals in the harness connectors. 6. Reconnect the six harness connectors and reinstall the CJB. 7. Reinstall the lower kick panel. NOTE IF ANY CORROSION WAS FOUND IN EITHER C263 OR THE CJB, THE SOURCE OF THE WATER ENTRY MUST BE IDENTIFIED TO PREVENT A REPEAT REPAIR. Follow standard water testing procedures to identify the source of any leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5204 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5205 Figures 4 through 8 identify some common sources of water leaks. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060903 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14A187 68 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set TSB 06-9-3 05/15/06 PCM FAILURE - ELECTRICAL ACCESSORIES INTERMITTENT - INOPERATIVE FORD: 2001-2004 Escape ISSUE Some vehicles may exhibit a powertrain control module (PCM) concern that results in no crank, no start, or malfunction indicator lamp (MIL) with one or more diagnostic trouble codes (DTCs) present. There may also be intermittent or inoperative power windows, door locks, keyless entry system, lighting, speed control, radio, instrument cluster warning lamps (possibly dimly illuminated instead of being off), or other electrical accessories. The concern is typically more noticeable in wet and/or cold weather conditions. This may be the result of connector terminal corrosion in C134, C263, or the central junction box (CJB) which results in either high resistance between the male and female terminals or a short between two or more circuits due to bridging through any corrosion that may be present. Corrosion in C134 may be the result of improper positioning/sealing of C134. Corrosion in C263 or the CJB may be due to a water leak in the left hand A-Pillar area. ACTION Follow the Service Procedure to inspect and repair the connector terminals for evidence of corrosion. Repair any sources of water entry. If no signs of corrosion or water entry are found, follow normal diagnostics. SERVICE PROCEDURE NOTE WHEN DIAGNOSING THE CAUSE OF A PCM FAILURE IT IS CRITICAL THAT THIS INSPECTION AND REPAIR PROCEDURE BE COMPLETED IN ITS ENTIRETY BEFORE INSTALLING A REPLACEMENT SERVICE PART. THE POSSIBILITY EXISTS FOR A 12 VOLT SHORT TO THE 5 VOLT VREF (CIRCUIT). INSTALLATION OF A SERVICE REPLACEMENT PCM WITHOUT ELIMINATING THE 12 VOLT SHORT WILL RESULT IN REPEAT PCM FAILURE. Inspect and repair the following connectors: C134 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5211 1. Open the hood and locate C134 (Figure 1). 2. Disconnect the connector halves and thoroughly inspect the terminals. Clean any corrosion that may be present and replace any damaged terminals. 3. Use shop air to blow out any moisture that may be present in the terminals, then apply dielectric grease to the terminals in both halves of the connector. 4. Reconnect the connector halves and close the hood. C263 1. Open the drivers door and remove the lower kick panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5212 2. Locate C263 as shown in Figure 2. 3. Disconnect the connector halves. 4. Pry out the terminal retainer as shown in Figure 3 and thoroughly inspect the terminals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5213 NOTE THE CORROSION WILL NOT BE VISIBLE UNLESS THE TERMINAL RETAINER IS REMOVED. 5. Clean any corrosion that may be present and replace any damaged terminals. 6. Work dielectric grease into the side opening in the connector, then reinstall the terminal retainer. 7. Apply dielectric grease to the terminals in both halves of the connector. 8. Reconnect the connector halves. CJB (Central Junction Box) 1. Locate the CJB (Figure 2). 2. Disconnect the four harness connectors from the front and the two connectors from the rear of the CJB, and remove the CJB. 3. Inspect the terminals and also the back side of the CJB or evidence of water damage or corrosion. 4. Clean any corrosion that may be present and replace any damaged terminals or components. 5. Apply dielectric grease to the terminals in the harness connectors. 6. Reconnect the six harness connectors and reinstall the CJB. 7. Reinstall the lower kick panel. NOTE IF ANY CORROSION WAS FOUND IN EITHER C263 OR THE CJB, THE SOURCE OF THE WATER ENTRY MUST BE IDENTIFIED TO PREVENT A REPEAT REPAIR. Follow standard water testing procedures to identify the source of any leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5214 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5215 Figures 4 through 8 identify some common sources of water leaks. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060903 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14A187 68 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 Multiple Junction Connector: Diagrams C110 - C311 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5218 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5219 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5220 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5221 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5222 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5223 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5224 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5225 Multiple Junction Connector: Diagrams C312 - C919 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5226 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5227 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5228 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5229 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5230 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5231 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Power Distribution Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Page 5235 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5240 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5244 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Power Distribution Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Page 5248 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5253 Relay Box: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5254 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Pin Number and Connector View Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5257 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5258 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5259 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5260 Relay Box: Diagrams Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5261 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5264 Relay Box: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5265 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5270 Relay Box: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5271 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Pin Number and Connector View Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5274 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5275 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5276 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5277 Relay Box: Diagrams Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5278 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5281 Relay Box: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5282 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 04-26-12 > Dec > 04 > SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set Wiring Harness: Customer Interest SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set TSB 04-26-12 12/31/04 SIDE AIR BAG DIAGNOSTIC TROUBLE CODE (DTC) B1994 OR B1998 FORD: 2001-2004 Escape ISSUE Some 2001-2004 Escape vehicles may exhibit the air bag warning lamp illuminating intermiffently with DTC B1994 (driver side, side mount air bag circuit open) or B1998 (passenger side, side mount air bag circuit open). This condition may be caused by a variation in the electrical continuity at connector C337 (passenger side) or C367 (driver side) at the body harness wire terminal crimp. ACTION Install a replacement body harness pigtail connector in the affected circuit. Refer to the instruction sheet included in the connector repair kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042612A 2001-2004 Escape One 1.2 Hrs. Seat: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat) 042612B 2001-2004 Escape Both 1.8 Hrs. Seats: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seats) DEALER CODING CONDITION BASIC PART NO. CODE 14405 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5296 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5297 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5298 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5299 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5300 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5301 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5302 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5303 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5304 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04-26-12 > Dec > 04 > SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set Wiring Harness: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set TSB 04-26-12 12/31/04 SIDE AIR BAG DIAGNOSTIC TROUBLE CODE (DTC) B1994 OR B1998 FORD: 2001-2004 Escape ISSUE Some 2001-2004 Escape vehicles may exhibit the air bag warning lamp illuminating intermiffently with DTC B1994 (driver side, side mount air bag circuit open) or B1998 (passenger side, side mount air bag circuit open). This condition may be caused by a variation in the electrical continuity at connector C337 (passenger side) or C367 (driver side) at the body harness wire terminal crimp. ACTION Install a replacement body harness pigtail connector in the affected circuit. Refer to the instruction sheet included in the connector repair kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042612A 2001-2004 Escape One 1.2 Hrs. Seat: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat) 042612B 2001-2004 Escape Both 1.8 Hrs. Seats: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seats) DEALER CODING CONDITION BASIC PART NO. CODE 14405 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5314 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5315 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5316 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5317 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5318 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5319 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5320 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5321 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5322 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5328 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5339 Fuse: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 5340 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5343 Fuse: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 5344 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5349 Fuse Block: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 5350 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5353 Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5354 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5355 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5356 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5359 Fuse Block: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 5360 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REMOVAL 1. Disconnect the battery cables. 2. NOTE: The 2.0L is shown, the 3.0L is similar. Remove the ground strap. 1 Remove the nut. 2 Remove the bolt. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5367 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5371 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set Multiple Junction Connector: Customer Interest Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set TSB 06-9-3 05/15/06 PCM FAILURE - ELECTRICAL ACCESSORIES INTERMITTENT - INOPERATIVE FORD: 2001-2004 Escape ISSUE Some vehicles may exhibit a powertrain control module (PCM) concern that results in no crank, no start, or malfunction indicator lamp (MIL) with one or more diagnostic trouble codes (DTCs) present. There may also be intermittent or inoperative power windows, door locks, keyless entry system, lighting, speed control, radio, instrument cluster warning lamps (possibly dimly illuminated instead of being off), or other electrical accessories. The concern is typically more noticeable in wet and/or cold weather conditions. This may be the result of connector terminal corrosion in C134, C263, or the central junction box (CJB) which results in either high resistance between the male and female terminals or a short between two or more circuits due to bridging through any corrosion that may be present. Corrosion in C134 may be the result of improper positioning/sealing of C134. Corrosion in C263 or the CJB may be due to a water leak in the left hand A-Pillar area. ACTION Follow the Service Procedure to inspect and repair the connector terminals for evidence of corrosion. Repair any sources of water entry. If no signs of corrosion or water entry are found, follow normal diagnostics. SERVICE PROCEDURE NOTE WHEN DIAGNOSING THE CAUSE OF A PCM FAILURE IT IS CRITICAL THAT THIS INSPECTION AND REPAIR PROCEDURE BE COMPLETED IN ITS ENTIRETY BEFORE INSTALLING A REPLACEMENT SERVICE PART. THE POSSIBILITY EXISTS FOR A 12 VOLT SHORT TO THE 5 VOLT VREF (CIRCUIT). INSTALLATION OF A SERVICE REPLACEMENT PCM WITHOUT ELIMINATING THE 12 VOLT SHORT WILL RESULT IN REPEAT PCM FAILURE. Inspect and repair the following connectors: C134 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5380 1. Open the hood and locate C134 (Figure 1). 2. Disconnect the connector halves and thoroughly inspect the terminals. Clean any corrosion that may be present and replace any damaged terminals. 3. Use shop air to blow out any moisture that may be present in the terminals, then apply dielectric grease to the terminals in both halves of the connector. 4. Reconnect the connector halves and close the hood. C263 1. Open the drivers door and remove the lower kick panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5381 2. Locate C263 as shown in Figure 2. 3. Disconnect the connector halves. 4. Pry out the terminal retainer as shown in Figure 3 and thoroughly inspect the terminals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5382 NOTE THE CORROSION WILL NOT BE VISIBLE UNLESS THE TERMINAL RETAINER IS REMOVED. 5. Clean any corrosion that may be present and replace any damaged terminals. 6. Work dielectric grease into the side opening in the connector, then reinstall the terminal retainer. 7. Apply dielectric grease to the terminals in both halves of the connector. 8. Reconnect the connector halves. CJB (Central Junction Box) 1. Locate the CJB (Figure 2). 2. Disconnect the four harness connectors from the front and the two connectors from the rear of the CJB, and remove the CJB. 3. Inspect the terminals and also the back side of the CJB or evidence of water damage or corrosion. 4. Clean any corrosion that may be present and replace any damaged terminals or components. 5. Apply dielectric grease to the terminals in the harness connectors. 6. Reconnect the six harness connectors and reinstall the CJB. 7. Reinstall the lower kick panel. NOTE IF ANY CORROSION WAS FOUND IN EITHER C263 OR THE CJB, THE SOURCE OF THE WATER ENTRY MUST BE IDENTIFIED TO PREVENT A REPEAT REPAIR. Follow standard water testing procedures to identify the source of any leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5383 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5384 Figures 4 through 8 identify some common sources of water leaks. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060903 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14A187 68 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set TSB 06-9-3 05/15/06 PCM FAILURE - ELECTRICAL ACCESSORIES INTERMITTENT - INOPERATIVE FORD: 2001-2004 Escape ISSUE Some vehicles may exhibit a powertrain control module (PCM) concern that results in no crank, no start, or malfunction indicator lamp (MIL) with one or more diagnostic trouble codes (DTCs) present. There may also be intermittent or inoperative power windows, door locks, keyless entry system, lighting, speed control, radio, instrument cluster warning lamps (possibly dimly illuminated instead of being off), or other electrical accessories. The concern is typically more noticeable in wet and/or cold weather conditions. This may be the result of connector terminal corrosion in C134, C263, or the central junction box (CJB) which results in either high resistance between the male and female terminals or a short between two or more circuits due to bridging through any corrosion that may be present. Corrosion in C134 may be the result of improper positioning/sealing of C134. Corrosion in C263 or the CJB may be due to a water leak in the left hand A-Pillar area. ACTION Follow the Service Procedure to inspect and repair the connector terminals for evidence of corrosion. Repair any sources of water entry. If no signs of corrosion or water entry are found, follow normal diagnostics. SERVICE PROCEDURE NOTE WHEN DIAGNOSING THE CAUSE OF A PCM FAILURE IT IS CRITICAL THAT THIS INSPECTION AND REPAIR PROCEDURE BE COMPLETED IN ITS ENTIRETY BEFORE INSTALLING A REPLACEMENT SERVICE PART. THE POSSIBILITY EXISTS FOR A 12 VOLT SHORT TO THE 5 VOLT VREF (CIRCUIT). INSTALLATION OF A SERVICE REPLACEMENT PCM WITHOUT ELIMINATING THE 12 VOLT SHORT WILL RESULT IN REPEAT PCM FAILURE. Inspect and repair the following connectors: C134 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5390 1. Open the hood and locate C134 (Figure 1). 2. Disconnect the connector halves and thoroughly inspect the terminals. Clean any corrosion that may be present and replace any damaged terminals. 3. Use shop air to blow out any moisture that may be present in the terminals, then apply dielectric grease to the terminals in both halves of the connector. 4. Reconnect the connector halves and close the hood. C263 1. Open the drivers door and remove the lower kick panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5391 2. Locate C263 as shown in Figure 2. 3. Disconnect the connector halves. 4. Pry out the terminal retainer as shown in Figure 3 and thoroughly inspect the terminals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5392 NOTE THE CORROSION WILL NOT BE VISIBLE UNLESS THE TERMINAL RETAINER IS REMOVED. 5. Clean any corrosion that may be present and replace any damaged terminals. 6. Work dielectric grease into the side opening in the connector, then reinstall the terminal retainer. 7. Apply dielectric grease to the terminals in both halves of the connector. 8. Reconnect the connector halves. CJB (Central Junction Box) 1. Locate the CJB (Figure 2). 2. Disconnect the four harness connectors from the front and the two connectors from the rear of the CJB, and remove the CJB. 3. Inspect the terminals and also the back side of the CJB or evidence of water damage or corrosion. 4. Clean any corrosion that may be present and replace any damaged terminals or components. 5. Apply dielectric grease to the terminals in the harness connectors. 6. Reconnect the six harness connectors and reinstall the CJB. 7. Reinstall the lower kick panel. NOTE IF ANY CORROSION WAS FOUND IN EITHER C263 OR THE CJB, THE SOURCE OF THE WATER ENTRY MUST BE IDENTIFIED TO PREVENT A REPEAT REPAIR. Follow standard water testing procedures to identify the source of any leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5393 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 06-9-3 > May > 06 > Electrical - Intermit. No Crank/Start/MIL ON/DTC's Set > Page 5394 Figures 4 through 8 identify some common sources of water leaks. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060903 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14A187 68 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 Multiple Junction Connector: Diagrams C110 - C311 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5397 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5398 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5399 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5400 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5401 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5402 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5403 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5404 Multiple Junction Connector: Diagrams C312 - C919 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5405 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5406 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5407 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5408 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5409 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C311 > Page 5410 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Power Distribution Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Page 5414 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5419 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5423 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection Power Distribution Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Page 5427 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5432 Relay Box: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5433 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Pin Number and Connector View Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5436 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5437 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5438 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5439 Relay Box: Diagrams Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5440 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5443 Relay Box: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5444 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5449 Relay Box: Locations Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 5450 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box Relay Box: Diagrams Central Junction Box Pin Number and Connector View Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5453 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5454 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5455 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5456 Relay Box: Diagrams Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Central Junction Box > Page 5457 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5460 Relay Box: Application and ID Central Junction Box Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 5461 Note: The fuse panel is located on the left hand side kick panel. Remove the panel cover to access the fuses. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 04-26-12 > Dec > 04 > SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set Wiring Harness: Customer Interest SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set TSB 04-26-12 12/31/04 SIDE AIR BAG DIAGNOSTIC TROUBLE CODE (DTC) B1994 OR B1998 FORD: 2001-2004 Escape ISSUE Some 2001-2004 Escape vehicles may exhibit the air bag warning lamp illuminating intermiffently with DTC B1994 (driver side, side mount air bag circuit open) or B1998 (passenger side, side mount air bag circuit open). This condition may be caused by a variation in the electrical continuity at connector C337 (passenger side) or C367 (driver side) at the body harness wire terminal crimp. ACTION Install a replacement body harness pigtail connector in the affected circuit. Refer to the instruction sheet included in the connector repair kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042612A 2001-2004 Escape One 1.2 Hrs. Seat: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat) 042612B 2001-2004 Escape Both 1.8 Hrs. Seats: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seats) DEALER CODING CONDITION BASIC PART NO. CODE 14405 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5475 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5476 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5477 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5478 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5479 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5480 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5481 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5482 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5483 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 04-26-12 > Dec > 04 > SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set Wiring Harness: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC's B1994 or B1998 Set TSB 04-26-12 12/31/04 SIDE AIR BAG DIAGNOSTIC TROUBLE CODE (DTC) B1994 OR B1998 FORD: 2001-2004 Escape ISSUE Some 2001-2004 Escape vehicles may exhibit the air bag warning lamp illuminating intermiffently with DTC B1994 (driver side, side mount air bag circuit open) or B1998 (passenger side, side mount air bag circuit open). This condition may be caused by a variation in the electrical continuity at connector C337 (passenger side) or C367 (driver side) at the body harness wire terminal crimp. ACTION Install a replacement body harness pigtail connector in the affected circuit. Refer to the instruction sheet included in the connector repair kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042612A 2001-2004 Escape One 1.2 Hrs. Seat: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat) 042612B 2001-2004 Escape Both 1.8 Hrs. Seats: Check For Diagnostic Trouble Codes, Install A Replacement Body Harness Pigtail (Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seats) DEALER CODING CONDITION BASIC PART NO. CODE 14405 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5493 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5494 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5495 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5496 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5497 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5498 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5499 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5500 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service Tips > Page 5501 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics Alignment: By Symptom Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5511 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5512 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5513 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > By Symptom for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5514 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics Alignment: All Technical Service Bulletins Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5520 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5521 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5522 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5523 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Front Position - Curb Caster .................................................................................................................................................. .................................................... 1.79° ± 1.00° Caster Split ............................................................... .................................................................................................................................... -1° to +1° Camber ................................................................................................................................................ .................................................. -0.48° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Total Toe ...................................................................................................................................................... .......................................... 0.08° ± 0.32° Ride Height ......................................................................... .......................................................................................................... 476.6 mm ± 20 mm Side-to-Side Lean ................................................................................................................................ .......................................... -10 mm to +10 mm Position - 8 gal. fill Caster .................................................................................................................................................. .................................................... 1.72° ± 1.00° Caster Split ............................................................... .................................................................................................................................... -1° to +1° Camber ................................................................................................................................................ .................................................. -0.48° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Total Toe ...................................................................................................................................................... ............................................ 0.08 ± 0.32° Ride Height ........................................................................ ........................................................................................................... 477.4 mm ± 20 mm Side-to-Side Lean ................................................................................................................................ .......................................... -10 mm to +10 mm Rear Position - Curb Camber ................................................................................................................................................ .................................................. -0.04° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Indiv. Toe ...................................................................................................................................................... ......................................... 0.04° ± 0.17° Ride Height .......................................................................... ............................................................................................................ 491 mm ± 20 mm Side-to-Side Lean ..................................................................................................................................................... ..................... -10 mm to +10 mm Clear Vision .................................................................................... ..................................................................................................................... 0 ± 3 Position - 8 gal. fill Camber ................................................................................................................................................ .................................................. -0.13° ± 1.00° Camber Split .............................................................. ................................................................................................................................... -1° to +1° Indiv. Toe ...................................................................................................................................................... ......................................... 0.04° ± 0.17° Ride Height .......................................................................... ............................................................................................................ 495 mm ± 20 mm Side-to-Side Lean ..................................................................................................................................................... ..................... -10 mm to +10 mm Clear Vision .................................................................................... ..................................................................................................................... 0 ± 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5526 Alignment: Specifications Torque Specifications Front shock absorber upper mounting bracket nuts .................................................................................................................................. 80 Nm (59 ft. lbs.) Rear suspension trailing arm and bushing bolts ...................................................................................................................................... 115 Nm (41 ft. lbs.) Tie rod end jam nuts .................................................................................................................... ............................................................. 55 Nm (41 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5527 Alignment: Description and Operation Suspension System The front suspension system consists of the following components ^ strut and spring assembly upper mounting bracket ^ upper spring seat ^ wheel hub ^ lug bolts ^ front wheel bearing ^ front suspension lower arm ball joints ^ front wheel knuckle ^ front stabilizer bar and brackets ^ front suspension lower and mounting bolt bushing (horizontal) ^ strut and spring assembly ^ stabilizer control link The front strut and spring assemblies can be disassembled to install any of the new individual components. New LH or RH front strut and spring assemblies can be installed independently. The front suspension system can also be disassembled in order to install new: ^ front wheel knuckle ^ wheel hub ^ lug bolts ^ front wheel bearing ^ front suspension lower arms ^ front suspension lower arm mounting bolt bushings (horizontal) New front stabilizer bar components can be installed individually. The rear suspension system consists of the following components: ^ rear spring ^ rear shock absorber ^ rear wheel knuckle and bushing ^ lower lateral link ^ upper lateral link ^ bump stopper New LH and RH rear wheel knuckles can be installed individually. The rear suspension arm and bushings can be installed individually. Only toe can be adjusted on the rear suspension. Wheel Alignment Angles Camber Camber is the inward or outward tilting of the wheels at the top. When the wheel tilts out at the top, then the camber is positive (+). When the wheel tilts in at the top, then the camber is negative (-). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5528 Caster Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. Front caster should fall within specification when the front camber is adjusted. Toe Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in toward the front of the vehicle, toe is positive (+) (toe inch). When the wheels are turned out toward the front of the vehicle, toe is negative (-) (toe out). Toe is measured in degrees, from side to side, and totaled. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Raise and support the vehicle. 2. Remove the front shock absorber upper mounting bracket nuts. 3. Push the front shock absorber upper mounting bracket downward and turn it to the desired position to set camber and caster. Both camber and caster for front suspension are adjustable within a maximum of 30 minutes angle. 4. Tighten the front shock absorber upper mounting bracket nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 5531 Alignment: Service and Repair Front Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and lock the steering wheel in position. 3. Check the toe settings. Follow the equipment manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie rod is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie rod threads. 6. Rotate the front wheel spindle tie rods. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 5532 7. Tighten the nuts. 8. Install the clamp(s). 9. Recheck the toe settings. Follow the equipment manufacturer's instructions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 5533 Alignment: Service and Repair Rear Toe Adjustment Rear Toe Adjustment 1. NOTE: Jounce the vehicle to make sure that the suspension is in its normal resting position. Check the toe setting using suitable wheel alignment equipment. 2. Loosen the LH and RH rear suspension trailing arm and bushing bolt. 3. Turn the LH and RH adjusting cams simultaneously until the toe is within specification. 4. Tighten the LH and RH rear suspension trailing arm and bushing bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 5534 Alignment: Service and Repair Lean Correction Lean Correction NOTE: When installing a new coil spring, install a new one with the same part number and the same spring code. Refer to the Vehicle Certification (VC) Label on the driver side door. 1. Measure the distance from the wheelhouse opening to the center of the wheel and tire at the same point on both sides of the vehicle. 2. If the difference exceeds 10 mm (0.4 inch), a lean correction is necessary. Compare the original with a new coil spring. Note the difference. 3. Remove the higher side coil spring. 1 If the original coil spring exceeds the height of the new one by 10 mm (0.4 inch), install the new coil spring in the vehicle. 2 If the original coil spring is shorter than the new one by 10 mm (0.4 inch), remove the low side coil spring from the vehicle. 4. Compare all three coil springs and select the two most evenly matched for installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Wheel knuckle cam bolt ....................................................................................................................... .................................................. 115 Nm (85 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5566 Front Steering Knuckle: Service and Repair Part 1 Of 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5567 Part 2 Of 2 Special Tool(s) Removal All vehicles NOTE: When a new wheel knuckle is installed a new wheel bearing must also be installed. 1. Remove the brake shoes. 2. NOTE: If equipped, remove ABS sensor ring. Remove the wheel hub nut. 3. Using the special tools, remove the wheel hub. 4. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tools press the inner wheel bearing race from the wheel hub. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5568 5. Remove the snap ring. Vehicles with ABS 6. Position the Anti-Lock Brake Sensor (ABS) aside. 1 Remove the ABS sensor bolt and bracket bolts. 2 Position the ABS sensor aside. All vehicles 7. Disconnect the parking brake cable from the brake backing plate. ^ Remove the parking brake cable bolt from the wheel knuckle. 8. Disconnect the brake line from the wheel cylinder. ^ Remove the brake line bracket bolt. 9. Support the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5569 10. Remove the lower shock absorber nut. 11. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Separate the lower ball joint from the wheel knuckle. 1 Remove the nut. 2 Separate the lower ball joint from the wheel knuckle. 12. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Separate the upper ball joint from the wheel knuckle. 1 Remove the nut. 2 Separate the upper ball joint from the wheel knuckle. 13. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5570 14. Remove the wheel knuckle cam bolt. 1 Mark the position of the adjustment cam notch. 2 Remove the wheel knuckle cam bolt. 15. Remove the wheel knuckle. 1 Remove the wheel knuckle cam. 2 Remove the wheel knuckle. 16. Remove the brake backing plate from the wheel knuckle. 1 Remove the bolts. 2 Remove the brake backing plate from the wheel knuckle. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5571 2. Install the snap ring into the wheel knuckle. 3. Position the brake backing plate to the wheel knuckle and install the bolts. 4. Using the wheel hub washer and the special tool, install the wheel hub into the wheel bearing. 5. NOTE: If equipped, install the ABS sensor ring. Install the wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5572 6. Position the wheel knuckle and install the wheel knuckle cam. 7. Install the wheel knuckle cam bolt loosely. 8. Support the wheel knuckle and install the spring. 9. Install the lower shock absorber nut. 10. Position the upper ball joint and install the nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5573 11. Position the lower ball joint and install the nut. 12. Tighten the wheel knuckle cam bolt. 1 Align the wheel knuckle cam. 2 Tighten the wheel knuckle cam bolt. 13. Connect the brake line to the wheel cylinder. ^ Install the brake line bracket bolt. 14. Install the parking brake cable through the brake backing plate. 1 Install the bolt. 2 Install the parking brake cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 5574 Vehicles with ABS 15. Position the ABS sensor and bracket bolts. ^ Install the bolts. All vehicles 16. Install the brake shoes. 17. Bleed the brake system. 18. Check and adjust the wheel alignment as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Purging Special Tools Special Tool(s) CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. NOTE: A whine heard from the power steering pump may be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the power steering pump reservoir cap. Check the fluid. ^ Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or equivalent MERCON fluid. 2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle. 4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed at idle. 5. Release the vacuum and remove the vacuum pump. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 5579 6. CAUTION: Do not overfill the reservoir. Fill the reservoir. ^ Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent. 7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. 8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum, and remove the vacuum pump. 10. Install the reservoir cap. 11. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 5584 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid capacity .............................................................................................................................................................. 1.9 Liters (2.0 quarts) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 5587 Power Steering Fluid: Fluid Type Specifications Premium Power Steering Fluid F7AZ-3F823-BA ................................................................................................................................................ MERCON Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Power steering fluid cooler mounting bolts .......................................................................................................................................... 10 Nm (89 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 5591 Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Removal and Installation 1. Disconnect the hose from the power steering fluid reservoir. 2. Disconnect the power steering cooler hose. 3. Remove the front bumper cover. 4. Remove the nuts and the power steering fluid cooler. 5. To install, reverse the removal procedure. Fill, bleed and leak check the power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications Power Steering Fluid Reservoir: Mechanical Specifications Power steering pump fluid reservoir mounting bolts ............................................................................................................................ 10 Nm (89 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications > Page 5596 Power Steering Fluid Reservoir: Capacity Specifications Fill to the line on the reservoir. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications > Page 5597 Power Steering Fluid Reservoir: Fluid Type Specifications Power Steering Fluid Power Steering Fluid Type Motorcraft Mercon ATF Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 5598 Power Steering Fluid Reservoir: Service and Repair Removal and Installation 1. NOTE: Drain the power steering fluid into a suitable drain pain. Disconnect the power steering fluid return hose. 2. Disconnect the power steering low pressure hose. 3. Remove the bolts and the power steering pump reservoir. 4. To install, reverse the removal procedure. ^ Fill power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power steering pressure hose to steering gear fitting ..................................................................................................................... 28-33 Nm (21-25 ft. lbs.) Power steering pressure line-to-pump fitting ........................................................................................................................................... 65 Nm (48 ft. lbs.) Power steering pressure line bracket-to-engine bolt ................................................................................................................................ 25 Nm (18 ft. lbs.) Power steering pressure and return line retainer plate-to-gear bolt .......................................................................................................... 25 Nm (18 ft. lbs.) Power steering pressure line bracket-to-gear bolt ................................................................................................................................ 10 Nm (89 inch lbs.) Power steering return line bracket-to-gear bolt .................................................................................................................................... 10 Nm (89 inch lbs.) Power steering pressure line bracket-to-lifting eye bolt ....................................................................................................................... 10 Nm (89 inch lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Special Tools Special Tool(s) Removal 1. Raise and support the vehicle. 2. NOTE: Drain the excess power steering fluid into a suitable drain pan. Disconnect the power steering pressure line from the power steering pump. 3. Lower the vehicle. 4. NOTE: Do not drop the O-ring seals. Disconnect the power steering pressure and return lines. 1 Remove the bolt. 2 Disconnect the power steering pressure and return lines. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 5604 5. Remove the power steering pressure line bracket bolt to the steering gear. 6. Remove the power steering pressure line bracket bolt to the engine lifting hook. 7. Remove the power steering pressure line bracket to engine bolt and the power steering pressure line. Installation 1. Using the special tool, install a new seal on the power steering pressure line fitting. ^ Remove and discard the original seal. ^ Stretch the seal over the special tool and slide it onto the tube nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 5605 2. Install the power steering pressure line bracket to engine bolt. 3. Install the power steering pressure line bracket bolt to the engine lifting hook. 4. Install the power steering pressure line bracket bolt to the steering gear. 5. NOTE: Make sure the O-ring seals are on the power steering pressure and return lines. Connect the power steering pressure and return lines to the steering gear and install the bolt. 6. Raise the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 5606 7. Connect the power steering pressure line to the power steering pump. 8. Lower the vehicle. 9. Fill, bleed and leak check the power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 5607 Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Removal and Installation 1. NOTE: Drain the excess power steering fluid into a suitable drain pan. NOTE: Make sure not to drop the O-ring seals. Disconnect the power steering pressure and return lines. 1 Remove the bolt. 2 Disconnect the power steering pressure and return lines. 2. Remove the power steering return line bracket-to-gear bolt. 3. Release the clamp and remove the power steering return line. 4. NOTE: Make sure the O-ring seals are on the power steering pressure and return lines. To install, reverse the removal procedure. ^ Fill, bleed and leak check the power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Power steering pump mounting bolts ....................................................................................................................................................... 15 Nm (18 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5612 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Power Steering Pump Flow (1) ................................................................................................................................................ ................... 6-8.25 liters/minute (1.79-2.19 gpm) Pressure (1) ........................................................... .................................................................................................................................. 414 kPa (60 psi) Relief pressure ......................................................................................................................................................... 8,964- 10,205 kPa (1,300-1,480 psi) (1)Fluid 74°-80° C (165°-175° F) Engine at idle Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5613 Power Steering Pump: Capacity Specifications Power Steering Pump Minimum capacity (1) .......................................................................................................................................................... 4.4 liters/minute (1.15 8pm) (1) Fluid @ 74°-80° C (165°-175° F). Engine at idle. Pressure at 5,171 kPa (750 psi) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Power Steering Pump Special Tool(s) Removal 1. Remove the accessory drive belt. 2. Disconnect the electrical connector. 3. NOTE: Drain the power steering fluid into a suitable drain pan. Disconnect the power steering pressure line. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5616 4. Remove the lower power steering pump bolts. 5. Lower the vehicle. 6. Remove the power steering pressure line bracket bolt. 7. Disconnect the power steering low pressure hose. 8. Remove the bolts and the power steering pump. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5617 9. Using the special tool, remove the power steering pump pulley. Installation 1. CAUTION: Install a new power steering pump pulley after the second removal and installation. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, install a new pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Using the special tool, install the power steering pump pulley. 2. Using the special tool, install a new seal on the power steering pressure hose fitting. ^ Remove and discard the original seal. ^ Stretch the seal over the seal replacer and slide it onto the tube nut. 3. Position the power steering pump and install the upper bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5618 4. Connect the power steering low pressure hose. 5. Position the power steering pressure line bracket and install the bolt. 6. Raise the vehicle. 7. Install the lower power steering pump bolts. 8. Connect the power steering pressure line, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5619 9. Connect the electrical connector. 10. Install the drive belt. 11. Fill, bleed and leak check the power steering system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5620 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley Removal and Installation 1. Loosen the power steering pump pulley bolt. 2. Remove the drive belt. 3. Remove the bolt and the power steering pump pulley. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions Power Steering Pressure Switch: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Power Steering Pressure Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5653 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5654 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5655 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5656 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5657 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5658 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Power Steering Gear Turning effort ....................................................................................................................................... .................................................... 30 Nm (6.75 lb) Steering gear mounting bolts ............................................................................................................... ................................................... 126 Nm (93 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Steering Gear: Service and Repair Steering Gear Steering Gear Special Tools Special Tool(s) Removal and Installation All vehicles 1. NOTE: 2.0L Zetec shown; 3.0L (4V) similar. Remove the rear transaxle insulator. 1 Remove the bolts and nuts. 2 Remove the rear transaxle insulator. Vehicles equipped with automatic transmission 2. Remove the bolts and the rear transaxle insulator bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5664 All vehicles 3. Remove the power steering pressure and return line bracket bolts. 4. Remove the front wheels. Vehicles equipped with manual transmission 5. Remove the bolts and the rear transaxle insulator bracket. All vehicles 6. NOTE: LH side shown; RH similar. Remove the tie rod end nut. 1 Remove the cotter pin. 2 Remove the nut. 7. NOTE: LH side shown; RH similar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5665 Using the special tool, separate the tie rod end from the knuckle. 8. NOTE: Record the number of turns required to remove the tie rod end. Remove the tie rod ends and the tie rod end jam nuts. 9. Remove the steering gear coupling pinch bolt. 1 Slide the boot up. 2 Remove the steering gear coupling pinch bolt. 10. NOTE: Drain the excess power steering fluid into a suitable drain pan. NOTE: Do not drop the O-ring seals. Disconnect the power steering pressure and return lines. 1 Remove the bolt. 2 Disconnect the power steering pressure and return lines. 11. Lower the vehicle on the hoist. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5666 12. Remove the steering shaft. 13. Remove the steering shaft boot. 1 Remove the nuts. 2 Remove the steering shaft boot. 14. NOTE: LH shown; RH similar. Remove the two steering gear mounting bolts. 15. Raise the vehicle on the hoist. NOTE: With the mounting bolts removed, slide the gear forward to separate the steering coupling from the steering gear shaft. Remove the steering gear. Installation All vehicles 1. NOTE: With the mounting bolts removed, slide the gear rearward to connect the steering coupling to the steering gear shaft. Position the steering gear in the vehicle. 2. Lower the hoist. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5667 3. Install the two steering gear mounting bolts. 4. Install the steering shaft boot. 5. Install the steering shaft. 6. Install the power steering pressure and return line bracket bolts. 7. Raise the vehicle on the hoist. 8. NOTE: Make sure the O-ring seals are on the power steering pressure and return lines. Connect the power steering pressure and return lines to the steering gear and install the bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5668 9. Install the steering gear coupling pinch bolt and slide the boot down. 10. Thread the tie rod end jam nuts onto the front wheel spindle tie rods. 11. NOTE: Use the numbers recorded from removal to install the tie rod ends. Thread the tie rod ends onto the front wheel spindle tie rods. 12. Tighten the tie rod end jam nuts. 13. NOTE: LH side shown; RH similar. Connect the tie rod end to the knuckle. 1 Install the nut. 2 Install the cotter pin. Vehicles equipped with manual transmission Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5669 14. Install the rear transaxle insulator bracket and the bolts. All vehicles 15. Install the front wheels. Vehicles equipped with automatic transmission 16. Install the rear transaxle insulator bracket and the bolts. All vehicles 17. NOTE: 2.0L Zetec shown; 3.0L (4V) similar. Install the rear transaxle insulator. 18. Fill, bleed and leak check the power steering system. 19. Align the front wheels to specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear > Page 5670 Steering Gear: Service and Repair Steering Gear Boot Steering Gear Boot Removal and Installation 1. Position the steering gear boot cover aside. 2. NOTE: The nut cannot be reused. Install a new nut. Disconnect the steering column shaft from the flexible coupling. 1 Remove and discard the nut. 2 Disconnect the steering column shaft from the flexible coupling. 3. Remove the steering gear boot. 1 Remove the nuts. 2 Remove the steering gear boot. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 5679 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 5685 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5691 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5692 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5698 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 5699 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5700 Steering Wheel: Service and Repair Removal 1. Position the front seats rearward. 2. Depower the supplemental restraint system (SRS). See: Steering Column/Air Bag(s) Arming and Disarming/Service and Repair/Air Bag Disarming and Arming/Depowering and Repowering Procedure 3. Lower the steering wheel air bag connector access cover. 4. Turn the pinion shaft to release the steering wheel from the column shaft. 5. Remove the steering wheel. - Position the steering wheel rearward. - Disconnect the electrical connector. Installation Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5701 1. Install the steering wheel. - Connect the electrical connector. - Position the steering wheel onto the steering column shaft. 2. Tighten the pinion shaft. 3. Close the steering wheel air bag connector access cover. 4. Repower the supplemental restraint system (SRS). See: Steering Column/Air Bag(s) Arming and Disarming/Service and Repair/Air Bag Disarming and Arming/Depowering and Repowering Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures Tie Rod End: Technical Service Bulletins Steering - Tie Rod End Inspection Procedures Article No. 03-15-13 08/04/03 STEERING - TIE ROD END INSPECTION PROCEDURE FORD: 1997-2002 EXPEDITION 1997-2003 F-150 2001-2004 ESCAPE LINCOLN: 1998-2002 NAVIGATOR 2002-2003 BLACKWOOD This article supersedes 03-9-9 to update the vehicle models covered. ISSUE This article is to be used as an updated procedure for inspecting tie rod end wear. ACTION This procedure is designed to supplement the Workshop Manual, as it provides a more detailed tie rod end inspection procedure. SERVICE INFORMATION NOTE FOR ESCAPE VEHICLES, THIS TIE ROD END INSPECTION PROCEDURE SHOULD ONLY BE COMPLETED ON THE OUTER TIE RODS. FOR ESCAPE INNER TIE ROD INSPECTION PROCEDURES, REFER TO WORKSHOP MANUAL SECTION 211-00. Step 1 - Free Play: Check the outer tie rod ends by grasping by hand and push up and down. Check the inner tie rod ends, pushing them front to rear. If any free play is observed in a joint, it is worn and should be replaced. Step 2 - Stud Lash - Free Play: While vehicle is on the ground or on a drive-on hoist, have an assistant rotate the steering wheel rapidly back and forth from 10 o'clock to 2 o'clock to 10 o'clock while observing the inner and outer tie rods. If the outer tie rod ends have any vertical movement or the inner tie rod ends have any horizontal movement, the tie rod end with the observed movement should be replaced. Step 3 - Seal Inspection: Raise the vehicle on a hoist and remove the front wheels. The wheels will need to be turned to the right in order to inspect the passenger side inner tie rod end and to the left to inspect the drivers side inner tie rod end. Inspect all four seals for tears, perforations and wear. If there is any indication of wear or perforations on the seal, that tie rod end should be replaced. Step 4 - Stud Corrosion: For Escape Vehicles - If Squeak is noticed during Step 2, disconnect tie rod from knuckle and articulate stud in socket. If squeak is verified, replace part. While pushing down on seal, at stud end, if corrosion present at contact point at base of stud, replace part. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 5707 For All Other Vehicles Covered In This Article: Using a wrench, rotate the tie rod end so that the front of the seal on the outer tie rod end is expanded (Figure 1). Using a puffy knife or other hard, flat, dull object, lift the bottom of the seal up, exposing the stud (Figure 2). If any water escapes from the seal in the form of bubbles or in a liquid form, that tie rod end should be replaced. Closely examine the stud for signs of corrosion, especially around the interface with the knuckle. A rag might be needed to clean off any grease on the stud that impairs a good visual inspection. If there is any sign of corrosion, that tie rod end should be replaced. Rotate the tie rod end in the opposite direction to expand the inner tie rod seal. Repeat the inspection procedure used on the outer tie rod. Repeat this entire procedure on the other side of the vehicle. If there is sign of corrosion, that tie rod end should be replaced. NOTE IF ANY TIE ROD ENDS ARE REMOVED, INSPECT THE SEAL AND THE STUD AGAIN NOTING ANY DIFFERENCES IN VISUAL PERCEPTIONS FROM WHEN THE PART WAS ON THE VEHICLE. CHECKING THE STUD AFTER REMOVAL HELPS IMPROVE CONSCIOUSNESS OF ISSUES WHEN INSPECTING PARTS ON VEHICLE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-9 WARRANTY STATUS: INFORMATION ONLY Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 5708 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 5709 Tie Rod End: Specifications Tie rod end lain nuts ............................................................................................................................ ..................................................... 55 Nm (41 ft. lbs.) Tie rod end nut ................................................. ........................................................................................................................................ 55 Nm (41 ft. lbs.) Tie rod end castellated ................................................................................................................ .............................................................. 50 Nm (17 ft. lbs.) Tie rod end jam nut ................................. .................................................................................................................................................. 45 Nm (33 ft. lbs.) Inner tie rod end ................................................................................................................ ...................................................................... 110 Nm (81 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner Tie Rod End-Inner Removal 1. Remove the steering gear. 2. NOTE: RH side shown; LH side similar. NOTE: It is necessary to remove both steering gear boots when removing the RH inner lie rod end. Remove the boot clamps and the steering gear boot. 3. NOTE: LH side shown; RH side similar. Using a suitable tool, hold the piston shaft. 4. NOTE: RH side shown; LH side similar. Using a suitable tool, remove the inner tie rod end. 5. NOTE: Using a suitable tool, hold the piston shaft while tightening. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 5712 Tie Rod End: Service and Repair Outer Tie Rod End-Outer Special Tools Special Tool(s) Removal and Installation 1. Turn the ignition switch to the unlock position. 2. Remove the tire and wheel assembly. 3. Remove the castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. 4. Loosen the tie rod end jam nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 5713 5. Using the special tool, separate the tie rod end 6. Remove the tie rod end. 7. To install, reverse the removal procedure. ^ Adjust the front toe. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Reference Diagram ............................................................................................................................. ............................................................................. D Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 5719 Ball Joint: Specifications General Specifications Front Ball joint pinch bolt ............................................................................................................................... .............................................. 70 Nm (52 ft. lbs.) Rear Lower ball joint nut ............................................................................................................................... ............................................ 115 Nm (85 ft. lbs.) Upper ball joint nut .................................................. ........................................................................................................................... 115 Nm (85 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection Ball Joint: Testing and Inspection Ball Joint Inspection Ball Joint Inspection 1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. 2. NOTE: In order to obtain accurate measurements, the suspension must be in full rebound with the weight of the vehicle supported by the frame. Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position. 3. Inspect the ball joint and ball joint boot for damage. ^ If the ball Joint or ball Joint boot is damaged, install a new ball joint as necessary. 4. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement. Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. ^ Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on the lower control arm by hand. Note any relative vertical movement between the wheel knuckle and lower arm at the lower ball joint. ^ If relative movement is not felt or seen, the ball Joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 5. 5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis (center line) of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower control arm and the wheel knuckle or ball joint stud. 6. Measure the ball joint deflection while an assistant pushes up and pulls down on the lower control arm, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. ^ If the deflection meets the specification, no further action is required. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 5722 Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Reference Diagram ............................................................................................................................. ............................................................................. D Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection Control Arm Bushing: Technical Service Bulletins Steering/Suspension - Control Arm Bushing Inspection TSB 09-5-1 03/23/09 LOWER CONTROL ARM BUSHING INSPECTION PROCEDURE FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Many states and Canadian provinces require annual safety inspections which include the evaluation of suspension components. The information in this procedure is intended to assist the technician performing the inspection with specific criteria for 2001-2009 Escape and Mariner lower control arm (LCA) bushings and will prevent the unnecessary replacement of good components. ACTION Inspect according to the procedure below. INSPECTION PROCEDURE The LCA bushing is located at the rear of the front suspension lower control arm. The bushing is identified as number 1 of Figure 1. The control arm is mounted in the front subframe with bolts number 2 and number 3. The bushing is part of the LCA and cannot be serviced separately from the arm. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection > Page 5728 Figure 2 - Shows a new bushing prior to assembly into the control arm. Bolt number 2 passes through the inner sleeve and the outer sleeve is pressed into the control arm. The rubber bushing is bonded to both the inner and outer sleeves. Figure 3 - Illustrates a generic bushing showing minor sur[ace cracks that do not adversely affect the performance of the bushing. Bushings exhibiting sur[ace cracks with a depth less than 3/8" (10 mm) are acceptable and will continue to function normally. These do not require replacement. Figure 4 - Illustrates a partial separation between the rubber and the outer sleeve. The bushing may show signs of movement on the rubber surface, making the surface shiny. Bushings with a separation or crack depth less than or equal to 3/8" (10 mm) are acceptable and meet all functional requirements. These do not require replacement. Bushings with a separation or crack greater than 3/8" (10 mm) in depth should be replaced. The customer may hear a bang or clunk in the front suspension if there is enough separation for the arm to contact the subframe. This does not affect the retention of the control arm to the vehicle as the bushing is sandwiched in the subframe and held in place with the bolt. The vehicle can be safely operated in this condition until the bushing is replaced. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Steering/Suspension - Control Arm Bushing Inspection > Page 5729 WARRANTY STATUS: Information Only Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Wheel knuckle cam bolt ....................................................................................................................... .................................................. 115 Nm (85 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5733 Front Steering Knuckle: Service and Repair Part 1 Of 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5734 Part 2 Of 2 Special Tool(s) Removal All vehicles NOTE: When a new wheel knuckle is installed a new wheel bearing must also be installed. 1. Remove the brake shoes. 2. NOTE: If equipped, remove ABS sensor ring. Remove the wheel hub nut. 3. Using the special tools, remove the wheel hub. 4. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tools press the inner wheel bearing race from the wheel hub. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5735 5. Remove the snap ring. Vehicles with ABS 6. Position the Anti-Lock Brake Sensor (ABS) aside. 1 Remove the ABS sensor bolt and bracket bolts. 2 Position the ABS sensor aside. All vehicles 7. Disconnect the parking brake cable from the brake backing plate. ^ Remove the parking brake cable bolt from the wheel knuckle. 8. Disconnect the brake line from the wheel cylinder. ^ Remove the brake line bracket bolt. 9. Support the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5736 10. Remove the lower shock absorber nut. 11. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Separate the lower ball joint from the wheel knuckle. 1 Remove the nut. 2 Separate the lower ball joint from the wheel knuckle. 12. NOTE: It may be necessary to hold the ball joint stud to keep it from turning while removing the nut. Separate the upper ball joint from the wheel knuckle. 1 Remove the nut. 2 Separate the upper ball joint from the wheel knuckle. 13. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5737 14. Remove the wheel knuckle cam bolt. 1 Mark the position of the adjustment cam notch. 2 Remove the wheel knuckle cam bolt. 15. Remove the wheel knuckle. 1 Remove the wheel knuckle cam. 2 Remove the wheel knuckle. 16. Remove the brake backing plate from the wheel knuckle. 1 Remove the bolts. 2 Remove the brake backing plate from the wheel knuckle. Installation All vehicles 1. Using the special tools, install a new wheel bearing into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5738 2. Install the snap ring into the wheel knuckle. 3. Position the brake backing plate to the wheel knuckle and install the bolts. 4. Using the wheel hub washer and the special tool, install the wheel hub into the wheel bearing. 5. NOTE: If equipped, install the ABS sensor ring. Install the wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5739 6. Position the wheel knuckle and install the wheel knuckle cam. 7. Install the wheel knuckle cam bolt loosely. 8. Support the wheel knuckle and install the spring. 9. Install the lower shock absorber nut. 10. Position the upper ball joint and install the nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5740 11. Position the lower ball joint and install the nut. 12. Tighten the wheel knuckle cam bolt. 1 Align the wheel knuckle cam. 2 Tighten the wheel knuckle cam bolt. 13. Connect the brake line to the wheel cylinder. ^ Install the brake line bracket bolt. 14. Install the parking brake cable through the brake backing plate. 1 Install the bolt. 2 Install the parking brake cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 5741 Vehicles with ABS 15. Position the ABS sensor and bracket bolts. ^ Install the bolts. All vehicles 16. Install the brake shoes. 17. Bleed the brake system. 18. Check and adjust the wheel alignment as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications Stabilizer bar bushing mount ............................................................................................................... ..................................................... 70 Nm (52 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Stabilizer bar links ............................................................................................................................... ..................................................... 43 Nm (32 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 5749 Stabilizer Link: Service and Repair Removal and Installation 1. Remove the wheel and tire. 2. Remove the stabilizer bar link. 1 Remove the upper and lower stabilizer bar link nuts. 2 Remove the stabilizer bar link. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5759 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5760 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises Front Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises > Page 5766 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises > Page 5767 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 5768 Front Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 5769 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 5770 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 5771 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 5772 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 5773 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 5774 Front Subframe: Service and Repair SUBFRAME - FRONT Special Tool(S) Special Tool(s) All vehicles 1. Disconnect the battery ground cable. 2. Remove the rear transmission mount nuts and bolt. 3. Using the special tool, support the engine. 4. Remove the two front wheel and tire assemblies. 5. Remove the two engine air deflectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 5775 6. Remove the two lower control arm ball joint pinch bolts and nuts (one on each side). 7. Disconnect the stabilizer bar link. 1 Remove the nuts. 2 Disconnect the link from the stabilizer bar. 8. Remove the lateral support crossmember. 1 Remove the belts. 2 Remove the crossmember. 9. Remove the front transmission mount bolt. 10. Remove the engine support crossmember bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 5776 11. Remove the nut and the engine support crossmember. 12. Remove the two steering gear bolts. 13. Position the steering gear out of the subframe mounts. 14. Remove the dual converter Y-pipe on the 3.0L (4V) engine or the muffler inlet pipe on the 2.0L (Zetec) engine. Vehicles with manual transmission 15. Remove the two bolts and disconnect the manual transmission shift linkage. Vehicles with 4WD 16. Remove the driveshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 5777 17. NOTE: Lower the rear of the engine to allow the subframe to clear the companion flange on the transfer case. Lower the rear of the engine approximately 150 mm (6 in). All vehicles 18. CAUTION: Do not allow the rear subframe bolts to come out of the lower control arm bushing. Completely loosen the two front subframe bolts, but do not remove them. 19. NOTE: The lower control arm ball joints must be disconnected from the spindles at the same time the subframe is lowered. With an assistant, remove the two subframe nuts lower the subframe from the vehicle. 20. Transfer all necessary components. 21. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5786 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5787 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5793 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5794 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 5795 Front Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 5796 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 5797 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 5798 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 5799 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 5800 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5809 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5810 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises Rear Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises > Page 5816 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises > Page 5817 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 5818 Rear Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 5819 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 5820 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 5821 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 5822 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 5823 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 5824 Rear Subframe: Service and Repair SUBFRAME - REAR Removal Vehicles with 4WD 1. Remove the rear axle assembly. All vehicles 2. Raise and support the vehicle. 3. Remove the four bolts and position the rear control arm aside. 4. Disconnect the exhaust hanger from the subframe. 5. With an assistant, remove the four bolts and rear subframe. Installation All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 5825 1. With an assistant, position the rear subframe and loosely install the bolts. 2. With a 19 mm (0.76 in) rod, align the rear subframe with the alignment holes. 3. Tighten the rear subframe bolts. 4. Connect the exhaust hanger on the subframe. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 5826 5. Position the four rear control arms in the subframe. - Loosely install the bolts. Vehicles with 4WD 6. Install the rear axle assembly. All vehicles 7. Lower the vehicle. 8. NOTE: The vehicles must be at ride height before tightening the bolts. Tighten the four control arms bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5835 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5836 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5842 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 5843 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 5844 Rear Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 5845 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 5846 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 5847 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 5848 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 5849 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair Suspension Spring ( Coil / Leaf ): Service and Repair Spring Removal and Installation NOTE: LH shown, RH similar. NOTE: After removing the wheel, finger-tighten one lug nut to retain the drum if the drum retainers have been removed. All vehicles 1. Remove the wheel and tire. 2. Disconnect the brake line from the wheel cylinder. ^ Remove the brake line bracket bolt. Vehicles with ABS 3. Position the anti-lock brake (ABS) sensor aside. 1 Remove the ABS sensor bolt and bracket bolts. 2 Position the ABS sensor aside. All vehicles 4. Support the rear wheel knuckle. 5. Remove the upper arm bolt. ^ Loosen the lower arm bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 5853 6. Remove the lower shock nut and position aside. 7. NOTE: Note the position of the spring insulator and spring for installation. Remove the spring. ^ Lower the support to the wheel knuckle. 8. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises Suspension Strut / Shock Absorber: Customer Interest Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises TSB 09-6-5 04/06/09 NOISE - FRONT STRUT AREA FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2001-2009 Escape, 2005-2009 Escape Hybrid, Mariner and 2006-2009 Mariner Hybrid vehicles may exhibit a pop, rub, grunt, squeak, and/or creak noise from the front strut area during slow, lock-to-lock turns such as parking maneuvers. Vehicles built on or before 1/13/2009 may also exhibit a clunk, crunch, thump, and/or knocking noise from the front strut area while driving over a series of bumps and/or rough roads. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Using chassis ears on the front strut mounts is pop, rub, grunt, squeak, creak, clunk, crunch, thump, and/or knocking noise present from the front strut area during slow parking lot type maneuvers? a. No - Procedure does not apply, proceed with normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes on turns - Boot may be binding, go to Step 2 Dust Boot Greasing Procedure. c. Yes over bumps (built on or before 1/13/2009) - Go to Step 3 Dust Boot Replacement Procedure and install new dust boot designed for this concern. d. Yes over bumps (built after 1/13/09) - Procedure does not apply. Proceed with normal WSM, Section 204-00 diagnostics. 2. Dust Boot Greasing Procedure. a. Raise the vehicle per WSM, Section 100-02. b. Reach through the spring and pull the strut dust boot and jounce bumper assembly straight down, out of the upper spring seat. c. Apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust cover. d. Raise dust cover so that jounce bumper is accessible and apply 360 degrees to the jounce bumper itself. e. Slide the dust cover and jounce bumper upward into its original location on the strut. f. Repeat the procedure on the other side of the vehicle. 3. Dust Boot Replacement Procedure (vehicles built on/before 1/13/2009). a. Remove front strut per WSM, Section 204-01. b. Disassemble front strut and replace dust boot with latest level part per WSM, Section 204-01. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5862 C. Apply Motorcraft Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust boot. (3) Apply 360 degrees to the jounce bumper itself. d. Assemble front strut and install per WSM, Section 204-01. e. Repeat the procedure on the other side of the vehicle. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090605A 2001-2009 Escape, 0.7 Hr. 2005-2009 Escape Hybrid, Mariner 2006-2009 Mariner Hybrid: Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test (Do Not Use With 1007D, 18124A) 090605B 2001-2009 Escape, 1.5 Hrs. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Replace The Strut Dust Boots, Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test Can Be Claimed With Operations C And D (Do Not Use With 1007D, 18124A) 090605C 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Check Caster, Camber and, Toe-In Can Be Claimed With Operation B And D (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090605D 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Correct Caster, Camber And Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5863 Toe-In Can Be Claimed With Operation B And C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 18A179 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises TSB 09-6-5 04/06/09 NOISE - FRONT STRUT AREA FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2001-2009 Escape, 2005-2009 Escape Hybrid, Mariner and 2006-2009 Mariner Hybrid vehicles may exhibit a pop, rub, grunt, squeak, and/or creak noise from the front strut area during slow, lock-to-lock turns such as parking maneuvers. Vehicles built on or before 1/13/2009 may also exhibit a clunk, crunch, thump, and/or knocking noise from the front strut area while driving over a series of bumps and/or rough roads. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Using chassis ears on the front strut mounts is pop, rub, grunt, squeak, creak, clunk, crunch, thump, and/or knocking noise present from the front strut area during slow parking lot type maneuvers? a. No - Procedure does not apply, proceed with normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes on turns - Boot may be binding, go to Step 2 Dust Boot Greasing Procedure. c. Yes over bumps (built on or before 1/13/2009) - Go to Step 3 Dust Boot Replacement Procedure and install new dust boot designed for this concern. d. Yes over bumps (built after 1/13/09) - Procedure does not apply. Proceed with normal WSM, Section 204-00 diagnostics. 2. Dust Boot Greasing Procedure. a. Raise the vehicle per WSM, Section 100-02. b. Reach through the spring and pull the strut dust boot and jounce bumper assembly straight down, out of the upper spring seat. c. Apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust cover. d. Raise dust cover so that jounce bumper is accessible and apply 360 degrees to the jounce bumper itself. e. Slide the dust cover and jounce bumper upward into its original location on the strut. f. Repeat the procedure on the other side of the vehicle. 3. Dust Boot Replacement Procedure (vehicles built on/before 1/13/2009). a. Remove front strut per WSM, Section 204-01. b. Disassemble front strut and replace dust boot with latest level part per WSM, Section 204-01. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5869 C. Apply Motorcraft Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust boot. (3) Apply 360 degrees to the jounce bumper itself. d. Assemble front strut and install per WSM, Section 204-01. e. Repeat the procedure on the other side of the vehicle. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090605A 2001-2009 Escape, 0.7 Hr. 2005-2009 Escape Hybrid, Mariner 2006-2009 Mariner Hybrid: Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test (Do Not Use With 1007D, 18124A) 090605B 2001-2009 Escape, 1.5 Hrs. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Replace The Strut Dust Boots, Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test Can Be Claimed With Operations C And D (Do Not Use With 1007D, 18124A) 090605C 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Check Caster, Camber and, Toe-In Can Be Claimed With Operation B And D (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090605D 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Correct Caster, Camber And Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-6-5 > Apr > 09 > Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises > Page 5870 Toe-In Can Be Claimed With Operation B And C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 18A179 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics Alignment: All Technical Service Bulletins Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5876 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5877 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5878 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5879 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5885 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5886 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5887 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 04-21-4 > Nov > 04 > Steering - Improved Drift/Pull Diagnostics > Page 5888 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Shock Absorber Front shock absorber upper mounting bracket nuts .................................................................................................................................. 80 Nm (59 ft. lbs.) Lower shock absorber nut ........................................................................................................... ............................................................ 115 Nm (85 ft. lbs.) Upper shock absorber ............................. .................................................................................................................................................. 18 Nm (13 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 5891 Suspension Strut / Shock Absorber: Specifications Strut Strut piston rod to bearing plate nut ........................................................................................................................................................ 103 Nm (76 ft. lbs.) Strut-to-wheel knuckle bolts ................................................................................. .................................................................................. 115 Nm (85 ft. lbs.) Upper strut mount bolts ..... .............................................................................................................................................................. ......... 80 Nm (59 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Installation Suspension Strut / Shock Absorber: Service and Repair Removal and Installation Strut and Spring Assembly Removal and Installation All vehicles 1. Remove the wheel and tire. 2. Unclip the brake hose from the bracket. Vehicles with ABS 3. Disconnect the anti-lock brake harness from the strut and spring assembly. 1 Remove the bolt. 2 Position the bracket aside. All vehicles 4. Position the stabilizer bar link aside. 1 Remove the upper stabilizer bar link nut. 2 Position the stabilizer bar link aside. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Installation > Page 5894 5. Remove the strut-to-wheel knuckle bolts. 6. Mark the bearing plate outer studs. Marking the studs will aid in the installation in restoring the caster/camber to its original settings. 7. NOTE: Support the strut and spring assembly when removing upper nuts. Remove the strut and spring assembly. ^ Remove the nuts. 8. To install, reverse the removal procedure. ^ Align the front wheels to specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Installation > Page 5895 Suspension Strut / Shock Absorber: Service and Repair Disassembly and Assembly Strut and Spring Assembly Disassembly and Assembly 1. Remove the strut and spring assembly. 2. WARNING: Always wear safety goggles when using a spring compressor. Failure to follow these instructions may result in personal injury. Mount the assembly in a suitable holding fixture and use a suitable spring compressor to compress the front coil spring. 3. Remove the strut piston rod nut. 4. Disassemble the strut and spring assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Installation > Page 5896 1 Remove the metal sheet plate. 2 Remove the upper strut mount. 3 Remove the thrust bearing plate. 4 Remove the thrust bearing. 5 Remove the upper spring seat. 6 Remove the upper spring seat isolator. 7 Remove the spring. 8 Remove the dust boot. 9 Remove the rubber bump stopper. 10 Remove the lower spring seat. 5. NOTE: New fasteners must be used when old fasteners are loosened and/or removed. NOTE: Make sure that an alignment procedure is carried out any time the strut and spring assembly or the front shock absorber mounting bracket bolts are loosened. NOTE: Be sure the spring is correctly seated in the insulator. To assemble, reverse the disassembly procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Installation > Page 5897 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Removal and Installation 1. Remove the rear quarter trim panel. 2. Remove the upper shock absorber nut. 3. Raise and support the vehicle enough to relax the suspension system. 4. Remove the shock absorber. ^ Remove the lower shock absorber nut. ^ Remove the shock absorber. 5. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection NOTE: The wheel bearings are not adjustable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5903 Removal NOTE: Install a new wheel bearing when the wheel hub is removed. All vehicles 1. Remove the brake disc. 2. Remove the wheel hub nut. 3. Remove the tie rod end nut. 1 Remove the cotter pin. 2 Remove the nut. 4. Using the special tool, separate the tie rod end from the knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5904 Vehicles with ABS 5. Remove the bolt and position the anti-lock brake sensor aside. All vehicles 6. Separate the lower ball joint from the wheel knuckle. 1 Remove the pinch bolt. 2 Separate the lower ball joint from the wheel knuckle. 7. Using the special tool, separate the halfshaft from the wheel knuckle. ^ Position the halfshaft aside and support. 8. Remove the wheel knuckle. 1 Remove the strut-to-wheel knuckle bolts. 2 Remove the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5905 9. Using the special tool, press the wheel hub from the wheel bearing and knuckle. 10. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 11. Remove the snap ring. 12. Using the special tools, press the outer wheel bearing race from the wheel knuckle. NOTE: The brake disc shield is pressed on. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5906 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5907 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. 1 Position the wheel knuckle. 2 Install the strut-to-wheel knuckle bolts. 6. Using the special tool, insert the halfshaft into the wheel hub. 7. Install the pinch bolt into the wheel knuckle. ^ Position and align the ball joint stud into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5908 Vehicles with ABS 8. Install the anti-lock brake sensor and tighten the bolt. All vehicles 9. Install the tie rod end into the wheel knuckle. 1 Install the tie rod end nut. 2 Install a new cotter pin. 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5909 Wheel Bearing: Service and Repair Rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5910 Special Tool(s) Removal 1. Remove the brake drum. 2. NOTE: If equipped, remove the ABS sensor ring. Remove the wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5911 3. Using the special tools, remove the wheel hub. 4. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 5. Remove the snap ring. 6. Using the special tools, remove the wheel bearing outer race from the wheel knuckle. Installation 1. Using the special tools, install the wheel bearing into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5912 2. Install the snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. 4. NOTE: If equipped, install the ABS sensor ring. Install the wheel hub nut. 5. Install the brake drum. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel hub nut ..................................................................................................................................... .................................................. 290 Nm (214 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. - Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury. CAUTION: The service jack provided with the vehicle is only intended to be used in an emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle. Jacking points - Front Jacking Points - Front 1. The front jacking point is at the bolt head of the lower control arm. Jacking points - Rear Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Lifting Points Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 5921 Lifting Points 1. CAUTION: Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. The lifting points are part of the uni-body structure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications Tires: Mechanical Specifications Tire Runout Specifications Type Wheel Aluminum Max. Radial Runout ............................................................................................................................. .................................... 1.5 mm (0.06 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Type Wheel Steel Max. Radial Runout ............................................................................................................................. .................................... 1.5 mm (0.06 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications > Page 5926 Tires: Pressure, Vacuum and Temperature Specifications Tire Inflation Tires ................................................................................................................................ See safety certification sticker located on the driver door jamb. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Specifications Wheels: Specifications Wheel Rim Runout Type Wheel Aluminum Max. Radial Runout ............................................................................................................................. ..................................... 1.5 mm (006 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Type Wheel Steel Max. Radial Runout ............................................................................................................................. ..................................... 1.5 mm (006 inch) Max. Lateral Runout ........................................................ ........................................................................................................ 2.0 mm (0.08 inch) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Specifications > Page 5930 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise the wheel integrity. Install a new wheel. Straightening Wheels, Rims or Components 1. NOTE: Do not heat wheels in an attempt to soften them for straightening to repair damage. The special alloy used in these wheels is heat-treated. Uncontrolled heating from welding affects the properties of the material. Do not weld the wheels for any reason. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection NOTE: The wheel bearings are not adjustable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5936 Removal NOTE: Install a new wheel bearing when the wheel hub is removed. All vehicles 1. Remove the brake disc. 2. Remove the wheel hub nut. 3. Remove the tie rod end nut. 1 Remove the cotter pin. 2 Remove the nut. 4. Using the special tool, separate the tie rod end from the knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5937 Vehicles with ABS 5. Remove the bolt and position the anti-lock brake sensor aside. All vehicles 6. Separate the lower ball joint from the wheel knuckle. 1 Remove the pinch bolt. 2 Separate the lower ball joint from the wheel knuckle. 7. Using the special tool, separate the halfshaft from the wheel knuckle. ^ Position the halfshaft aside and support. 8. Remove the wheel knuckle. 1 Remove the strut-to-wheel knuckle bolts. 2 Remove the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5938 9. Using the special tool, press the wheel hub from the wheel bearing and knuckle. 10. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 11. Remove the snap ring. 12. Using the special tools, press the outer wheel bearing race from the wheel knuckle. NOTE: The brake disc shield is pressed on. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5939 13. If necessary, remove the brake disc shield. Installation All vehicles 1. If necessary, install a disc brake shield. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5940 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. 1 Position the wheel knuckle. 2 Install the strut-to-wheel knuckle bolts. 6. Using the special tool, insert the halfshaft into the wheel hub. 7. Install the pinch bolt into the wheel knuckle. ^ Position and align the ball joint stud into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5941 Vehicles with ABS 8. Install the anti-lock brake sensor and tighten the bolt. All vehicles 9. Install the tie rod end into the wheel knuckle. 1 Install the tie rod end nut. 2 Install a new cotter pin. 10. Install the wheel hub nut. 11. Install the brake disc. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5942 Wheel Bearing: Service and Repair Rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5943 Special Tool(s) Removal 1. Remove the brake drum. 2. NOTE: If equipped, remove the ABS sensor ring. Remove the wheel hub nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5944 3. Using the special tools, remove the wheel hub. 4. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle, after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 5. Remove the snap ring. 6. Using the special tools, remove the wheel bearing outer race from the wheel knuckle. Installation 1. Using the special tools, install the wheel bearing into the wheel knuckle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5945 2. Install the snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. 4. NOTE: If equipped, install the ABS sensor ring. Install the wheel hub nut. 5. Install the brake drum. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel hub nut ..................................................................................................................................... .................................................. 290 Nm (214 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel nuts (all wheels) ....................................................................................................................... .................................................... 133 Nm (98 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal and Installation 1. Remove the front wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 5955 Wheel Fastener: Service and Repair Rear Removal and Installation 1. Remove the wheel bearing. 2. Press out the wheel studs. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions Accumulator HVAC: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 5960 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The suction accumulator is mounted to the A/C accumulator bracket. The inlet tube of the suction accumulator is connected to the A/C evaporator outlet tube. The outlet tube is connected to the A/C manifold and tube assembly. After entering the inlet of the suction accumulator, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. ^ A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. ^ As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. ^ A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. ^ A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. ^ A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 5961 Accumulator HVAC: Service and Repair REMOVAL 1. Recover the refrigerant. 2. Remove the A/C cycling switch. 3. Remove the nuts from the A/C manifold and tube mounting bracket. 4. Disconnect the A/C manifold and tube from the suction accumulator. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 5. Remove the two suction accumulator mounting bracket nuts. 6. Disconnect the suction line from the A/C evaporator core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 5962 CAUTION: Plug all ports to prevent contamination from dirt or moisture. 7. Remove the suction accumulator. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the new suction accumulator with the correct amount of PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Defrost Vacuum Control Motor Air Door Actuator / Motor: Service and Repair Defrost Vacuum Control Motor REMOVAL 1. Remove the vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the two screws. 3 Disconnect the vacuum control motor from the door lever. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Defrost Vacuum Control Motor > Page 5968 Air Door Actuator / Motor: Service and Repair Panel Vent Vacuum Control Motor REMOVAL 1. Remove the vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the two screws. 3 Disconnect the vacuum control motor from the door lever. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Defrost Vacuum Control Motor > Page 5969 Air Door Actuator / Motor: Service and Repair Footwell Vent Vacuum Control Motor REMOVAL 1. Remove the vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the two screws. 3 Disconnect the vacuum control motor from the door lever. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Defrost Vacuum Control Motor > Page 5970 Air Door Actuator / Motor: Service and Repair Outside Air Inlet Vacuum Control Motor REMOVAL 1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 2. Remove the vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the two screws. 3 Disconnect the vacuum control motor from the door lever. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair Air Door Cable: Service and Repair Alignment Pin, Temperature Blend Door SPECIAL TOOL(S) REMOVAL 1. Disconnect the negative battery cable. 2. Lower the glove compartment door. ^ Press the glove compartment release tabs inward while pulling downward on the glove compartment. 3. Disconnect the temperature blend door control cable. 1 Align the locator holes and insert the special tool. 2 Release the locking tab. 3 Remove the temperature blend door control cable from the blend door shaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Page 5974 4. Remove the instrument panel center finish panel. ^ Disconnect the electrical connectors. 5. Depress the three tabs and remove the temperature blend door control cable. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Rotate the gear to align the locking tab with the notch in the gear before installing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Page 5975 Alignment Pin, Temperature Blend Door Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct Air Duct: Service and Repair Defroster Duct REMOVAL 1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 2. Remove the screws and the retaining guides. 3. Remove the screws and remove the duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 5980 Air Duct: Service and Repair Rear Footwell Duct REMOVAL 1. Remove the driver and front passenger seats. 2. Remove the utility compartment. 1 Remove the four plastic fasteners. 2 Remove the utility compartment. ^ Disconnect the electrical connection. 3. Remove LH and RH front door scuff plates. 4. Remove LH and RH lower A-pillar panels. 5. Remove the LH foot rest. 6. Pull back the carpet to gain access to the rear floor vent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 5981 7. Remove the wire harness pin-type retainer. 8. Remove the floor duct pin-type retainers and remove the duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 5982 Air Duct: Service and Repair Center Register Duct REMOVAL 1. Remove the defroster duct. 2. Remove the screws from the front side of the instrument panel. 3. Remove the screw for the left vent duct. 4. Remove the screw for the right vent duct. 5. Remove the screws for the center vent duct and remove the vent duct. INSTALLATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct > Page 5983 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 04-25-13 > Dec > 04 > A/C - Instrument Panel Vents Hard to Adjust Air Register: Customer Interest A/C - Instrument Panel Vents Hard to Adjust TSB 04-25-13 12/27/04 SERVICEABILITY OF INSTRUMENT PANEL REGISTER VENTS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 vehicles may exhibit instrument panel (IP) register vents that are difficult to adjust or are limited in their adjustability. ACTION Register vents for the IP center finish panel can now be ordered and replaced individually. Replacement of an entire center finish panel assembly to correct a register vent condition is no longer necessary. The IP outboard register vents can be replaced similarly without replacing the entire housing assembly, however, the outboard vent must be ordered as an assembly with the housing. Refer to the following Service Procedure. SERVICE PROCEDURE CENTER REGISTER REPLACEMENT 1. Remove center finish panel. Refer to Workshop Manual Section 501-12. 2. With center finish panel removed, release the register retention tabs and remove the register. 3. Replace register with Part Number YL8Z-19893-CAA left or YL8Z-19893-CAB right. 4. Reinstall the center finish panel. OUTBOARD REGISTER REPLACEMENT 1. Tilt the vehicle's outboard register to the down most position. Pull the top of the register out until it is released from the housing. 2. Remove the new register from the service replacement register housing assembly (base # -19893-), as described in Step 1. 3. Snap the new register into the vehicle's existing outboard register housing. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042513A Register Replace Right 0.2 Hr. Outboard Vent Only 042513B Register Replace Left 0.2 Hr. Outboard Vent Only 042513C Register Replace Both 0.4 Hr. Center Vents (Includes Time To Remove And Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 04-25-13 > Dec > 04 > A/C - Instrument Panel Vents Hard to Adjust > Page 5992 Install Center Finish Panel) 042513D Register Replace All Vents 0.4 Hr. (Includes Time To Remove And Install Center Finish Panel) DEALER CODING CONDITION BASIC PART NO. CODE 19893 41 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 04-25-13 > Dec > 04 > A/C - Instrument Panel Vents Hard to Adjust Air Register: All Technical Service Bulletins A/C - Instrument Panel Vents Hard to Adjust TSB 04-25-13 12/27/04 SERVICEABILITY OF INSTRUMENT PANEL REGISTER VENTS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 vehicles may exhibit instrument panel (IP) register vents that are difficult to adjust or are limited in their adjustability. ACTION Register vents for the IP center finish panel can now be ordered and replaced individually. Replacement of an entire center finish panel assembly to correct a register vent condition is no longer necessary. The IP outboard register vents can be replaced similarly without replacing the entire housing assembly, however, the outboard vent must be ordered as an assembly with the housing. Refer to the following Service Procedure. SERVICE PROCEDURE CENTER REGISTER REPLACEMENT 1. Remove center finish panel. Refer to Workshop Manual Section 501-12. 2. With center finish panel removed, release the register retention tabs and remove the register. 3. Replace register with Part Number YL8Z-19893-CAA left or YL8Z-19893-CAB right. 4. Reinstall the center finish panel. OUTBOARD REGISTER REPLACEMENT 1. Tilt the vehicle's outboard register to the down most position. Pull the top of the register out until it is released from the housing. 2. Remove the new register from the service replacement register housing assembly (base # -19893-), as described in Step 1. 3. Snap the new register into the vehicle's existing outboard register housing. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042513A Register Replace Right 0.2 Hr. Outboard Vent Only 042513B Register Replace Left 0.2 Hr. Outboard Vent Only 042513C Register Replace Both 0.4 Hr. Center Vents (Includes Time To Remove And Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 04-25-13 > Dec > 04 > A/C - Instrument Panel Vents Hard to Adjust > Page 5998 Install Center Finish Panel) 042513D Register Replace All Vents 0.4 Hr. (Includes Time To Remove And Install Center Finish Panel) DEALER CODING CONDITION BASIC PART NO. CODE 19893 41 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6003 Blower Motor: Description and Operation Blower Motor The blower motor pulls air from the air inlet and forces it into the heater core housing where it is mixed and distributed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor Blower Motor: Service and Repair Blower Motor REMOVAL 1. Remove the RH A-pillar lower trim. 2. Remove the blower motor. 1 Disconnect the electrical connector. 2 Remove the washer screws. 3 Remove the blower motor and cover, lower the assembly from the housing. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 6006 Blower Motor: Service and Repair Blower Motor Wheel REMOVAL 1. Remove the blower motor. 2. Remove the blower motor wheel retainer from the motor shaft, and remove the wheel. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Install a new blower wheel retainer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6010 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6011 Blower Motor Relay: Description and Operation The blower motor relay supplies voltage to the blower motor and is activated when the key is ON and the function selector switch is in any position besides OFF. The blower motor relay is located under the instrument panel next to the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6012 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6013 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations View 151-19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6017 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6018 Blower Motor Resistor: Description and Operation The four-speed operation of the blower motor is achieved through the blower motor switch resistor and contains a thermal limiter which is used as a temperature protecting fuse. The assembly is located on the passenger side on the evaporator core housing behind the glove compartment. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the blower motor switch knob. 3. Remove the blower motor switch. ^ Depress the locking tab. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air gap between pulley and hub........................................................................................................... ...................................0.35-0.75 mm (0.014-0.029 in) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6029 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6030 Compressor Clutch: Description and Operation A/C compressor and Clutch Assembly NOTE: ^ Internal A/C compressor components are not repaired separately. Install a new FS-10 A/C compressor only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seals are repairable. ^ Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The FS-10 A/C compressor has the following characteristics: ^ a 10-cylinder swashplate design utilizing the tangential design mount ^ displacement of 170 cc (10.4 cubic inches) ^ A one-piece lip-type seal (repaired from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. ^ Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. ^ Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. ^ The A/C compressor uses PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. This oil contains special additives necessary for the A/C compressor. ^ The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: ^ It drives the compressor shaft. ^ When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6031 ^ The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. ^ When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch disc away from the A/C clutch pulley. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6032 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally-spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6033 Compressor Clutch: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Using the special tool, remove the A/C clutch bolt. 3. Remove the disk and hub assembly and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the disk and hub assembly and the A/C clutch hub spacer from the compressor shaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6034 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Using the special tools, remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Using the special tools, install the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6035 NOTE: Position the clutch field coil on the A/C compressor as previously marked. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the disk and hub assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6036 7. Using the special tool, install and tighten the A/C clutch bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6037 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6041 Compressor Clutch Coil: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6042 Compressor Clutch Coil: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Using the special tool, remove the A/C clutch bolt. 3. Remove the disk and hub assembly and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the disk and hub assembly and the A/C clutch hub spacer from the compressor shaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6043 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Using the special tools, remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Using the special tools, install the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6044 NOTE: Position the clutch field coil on the A/C compressor as previously marked. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the disk and hub assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6045 7. Using the special tool, install and tighten the A/C clutch bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6046 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 06-4-9 > Mar > 06 > A/C - Compressor Leaking/Inoperative Compressor Shaft Seal: All Technical Service Bulletins A/C - Compressor Leaking/Inoperative TSB 06-4-9 03/06/06 A/C COMPRESSOR NOT OPERATIONAL / LOW FREON-SHAFT SEAL LEAKS FORD: 2003 Escort 2003-2006 Focus, Mustang, Taurus 2003 Explorer Sport, Windstar 2003-2005 Excursion, Explorer Sport Trac 2003-2006 Escape, F-150, F-Super Duty, Ranger 2004-2006 Freestar 2006 Low Cab Forward LINCOLN: 2002 Blackwood 2006 Mark LT MERCURY: 2003-2005 Sable 2004-2006 Monterey 2005-2006 Mariner ISSUE Some 2002-2006 vehicles equipped with an FS-10 A/C compressor may experience a non operational A/C compressor due to a low freon level caused by a leaking shaft seal. ACTION Replace the A/C compressor shaft seal following the Service Procedure. SERVICE PROCEDURE If the shaft seal on the front of the A/C compressor is leaking, replace the shaft seal (F1VY-19D665-A) and not the compressor assembly. Replacing the shaft seal should correct the leaking condition. When replacing the seal, follow the procedure outlined in Workshop Manual, Section 412-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060409 Use Standard Labor Actual Operation For Compressor Time Removal And Installation If Available, And Claim Additional Labor Required As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19D665 42 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 06-4-9 > Mar > 06 > A/C - Compressor Leaking/Inoperative > Page 6055 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 06-4-9 > Mar > 06 > A/C Compressor Leaking/Inoperative Compressor Shaft Seal: Customer Interest A/C - Compressor Leaking/Inoperative TSB 06-4-9 03/06/06 A/C COMPRESSOR NOT OPERATIONAL / LOW FREON-SHAFT SEAL LEAKS FORD: 2003 Escort 2003-2006 Focus, Mustang, Taurus 2003 Explorer Sport, Windstar 2003-2005 Excursion, Explorer Sport Trac 2003-2006 Escape, F-150, F-Super Duty, Ranger 2004-2006 Freestar 2006 Low Cab Forward LINCOLN: 2002 Blackwood 2006 Mark LT MERCURY: 2003-2005 Sable 2004-2006 Monterey 2005-2006 Mariner ISSUE Some 2002-2006 vehicles equipped with an FS-10 A/C compressor may experience a non operational A/C compressor due to a low freon level caused by a leaking shaft seal. ACTION Replace the A/C compressor shaft seal following the Service Procedure. SERVICE PROCEDURE If the shaft seal on the front of the A/C compressor is leaking, replace the shaft seal (F1VY-19D665-A) and not the compressor assembly. Replacing the shaft seal should correct the leaking condition. When replacing the seal, follow the procedure outlined in Workshop Manual, Section 412-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060409 Use Standard Labor Actual Operation For Compressor Time Removal And Installation If Available, And Claim Additional Labor Required As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19D665 42 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 06-4-9 > Mar > 06 > A/C Compressor Leaking/Inoperative > Page 6061 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Page 6062 Compressor Shaft Seal: Service Precautions CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Page 6063 Compressor Shaft Seal: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the disk and hub assembly from the A/C compressor. 2. Using the special tool, remove the shaft seal felt from the nose of the A/C compressor. 3. Clean the compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 4. Using the special tool, remove the shaft seal snap ring. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Page 6064 5. Using the special tool, remove the shaft seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Lubricate the shaft seal and special tool with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Place the shaft seal on the special tool. 3. Position the special tool, with the shaft seal, over the A/C compressor shaft. 4. Using the special tool, push the shaft seal onto the A/C compressor shaft until seated. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Page 6065 5. Using the special tool, install the shaft seal snap ring. 6. Carry out the A/C compressor external leak test. 7. Using the special tool, install the shaft seal felt. 8. Install the disk and hub assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Page 6066 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6073 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6074 Compressor Clutch Relay: Description and Operation The A/C compressor clutch relay supplies voltage to the A/C compressor clutch and is located in the Battery Junction Box (BJB). The Power Control Module (PCM) can interrupt the A/C compressor operation through the A/C compressor clutch relay under the following conditions: ^ during engine start-up ^ Wide Open Throttle (WOT) ^ low engine idle conditions ^ excessively high engine temperatures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6075 Compressor Clutch Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6076 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions Compressor Fitting HVAC: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6080 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Remove the nuts from the A/C manifold and tube mounting bracket. 2. Disconnect the A/C manifold and tube from the suction accumulator. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 3. Remove the front bumper cover. 4. Remove the nut and disconnect the A/C manifold and tube to A/C condenser core air conditioning line (peanut) fitting. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 5. Position aside the speed control actuator assembly. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6081 1 Disconnect the electrical connector. 2 Disconnect the electrical harness pin-type retainers. 3 Remove the nuts. 6. Raise and support the vehicle. 7. Remove the RH splash shield. 8. If equipped, disconnect the engine block heater electrical connector. 9. Disconnect the A/C clutch field coil electrical connector. 10. Remove the A/C manifold and tube assembly bolt. CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service Precautions > Page 6082 NOTE: Vehicles with 2.0L Zetec engine shown, vehicles with 3.0L (4V) engine similar. 11. Remove the A/C manifold and tube assembly through the bottom of the vehicle. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. ^ Apply Pipe Sealant with Teflon (R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to the threads of the A/C manifold retaining bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions Condenser HVAC: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6086 Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The A/C condenser core has the following characteristics: ^ It is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator. ^ It cools compressed refrigerant gas by allowing air to pass over the fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6087 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45-minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. ^ If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. ^ If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. ^ If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service Precautions > Page 6088 Condenser HVAC: Service and Repair REMOVAL NOTE: ^ Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. ^ If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. 1. Recover the refrigerant. 2. Remove the front bumper cover. 3. Remove the nuts from the two condenser core air conditioning line (peanut) fittings. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 4. Remove the screws and the A/C condenser core brackets. 5. Remove the A/C condenser core. NOTE: When removing the A/C condenser core, disconnect the two air conditioning line (peanut) fittings from the A/C condenser core. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the new A/C condenser core with the correct amount of PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations View 151-19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views Control Assembly: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views > Page 6094 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6095 Control Assembly: Description and Operation The climate control assembly has three system controls: ^ The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. ^ The temperature selection is accomplished through cable-controlled positioning of the temperature blend door located in the heater core housing. ^ The blower motor switch controls the blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly Control Assembly: Service and Repair Climate Control Assembly REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the four screws and the climate control assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6098 Control Assembly: Service and Repair Temperature Control Switch TEMPERATURE CONTROL SWITCH Alignment Pin, Temperature Blend Door SPECIAL TOOL(S) REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the temperature control switch knob. 3. Disconnect the temperature blend door control cable. 1 Align the locator holes and insert the special tool. 2 Release the locking tab. 3 Remove the temperature blend door control cable from the blend door shaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6099 4. Depress the three tabs and remove the temperature blend door control cable. 5. Remove the temperature control switch. 1 Remove the screw. 2 Depress the tab and rotate the temperature control switch counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Rotate the gear to align the locking tab with the notch in the gear before installing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6100 Control Assembly: Service and Repair Function Selector Switch REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the function selector switch knob. 3. Remove the function selector switch. ^ Push in the locking tab on one side of the function selector switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Align the function selector switch locking tabs with the holes in the housing and press the function selector into the housing. Verify that both locking tabs are secured. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 6101 Control Assembly: Service and Repair Climate Control Assembly Illumination Bulbs REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the illumination bulb(s) by turning a quarter turn counterclockwise and lifting straight up. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Page 6102 Alignment Pin, Temperature Blend Door Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service Precautions Coupler HVAC: Service Precautions CAUTION: ^ Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. ^ Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. ^ Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. ^ Use only new green/purple O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. ^ Support the female fitting with a wrench to prevent the tubes from twisting. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service Precautions > Page 6106 Coupler HVAC: Description and Operation Spring Lock Coupling Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. ^ When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. ^ The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. ^ The O-ring seals are green in color and are made of a special material. ^ Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. ^ A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. ^ An A/C tube lock coupling clip may be used to secure the coupling but is not necessary. Air Conditioning Line (Peanut) Fitting The air conditioning line (peanut) fitting is an integral part of the refrigeration line or component. ^ The male and female blocks of the air conditioning line (peanut) fitting are retained with a nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service Precautions > Page 6107 ^ An O-ring seal is installed around the tube on the male block. ^ The female block is welded to the tube and is not adjustable. ^ Support the female fittings with a wrench to prevent twisting of the tubes. ^ The male block will pivot around the tube to allow for alignment with the female block during assembly. ^ When correctly assembled the male and female fittings should be flush. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Coupler HVAC: Service and Repair Spring Lock Coupling Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Recover the refrigerant. 2. Remove the A/C tube lock coupling clip. 3. Using the special tool, disengage the spring lock coupling fittings. 4. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6110 5. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite (R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed motor drill. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6111 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves or scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. ^ Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6112 3. Install the O-ring seals. 1 Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. NOTE: Some connections may have two or three O-ring seals. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. 5. Install the A/C tube lock coupling clip. 6. Charge the system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6113 Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting DISCONNECT 1. Recover the refrigerant. 2. Remove the nut from the air conditioning line (peanut) fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 3. Pull the air conditioning line (peanut) fitting apart. 4. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6114 2. Install the O-ring seal. 1 Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new purple O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled, the male and female fittings should be flush. 5. Charge the system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 6115 Spring Lock Coupling Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair REMOVAL 1. Discharge and recover the refrigerant. 2. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 3. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. 4. Disconnect the vacuum hose. 5. Remove the evaporator core housing. 1 Remove the nuts. 2 Carefully remove the evaporator core housing to avoid spilling PAG compressor oil in the passenger area. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ Feed the vacuum hose through the opening in the cowl while installing the housing. ^ Before installing the temperature control cable, make sure the blend door, cable and temperature switch are correctly positioned. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors Technical Service Bulletin # 03-5-6 Date: 030317 A/C - Musty or Mildew Type Odors Article No. 03-5-6 03/17/03 CLIMATE CONTROL - MUSTY OR MILDEW TYPE ODOR FROM CLIMATE CONTROL SYSTEM FORD: 2001-2003 ESCAPE ISSUE Some vehicles may exhibit a musty and/or mildew type odor coming from the climate control system. This odor is caused by mildew-type fungi growth in the A/C evaporator. It is most noticeable when the A/C is first turned on. ACTION Apply Motorcraft A/C Cooling Coil Coating to the A/C system, which encapsulates the mildew to help reduce odors. Install air inlet vacuum motor bleed valve, which operates the recirculation/fresh air door to default to fresh mode when the vehicle is parked to dry out the evaporator core. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030506A Apply Motorcraft A/C 1.5 Hrs. Cooling Coil Coating To The A/C System Then Install Air Inlet Vacuum Motor Bleed Valve DEALER CODING CONDITION BASIC PART NO. CODE 19B55 53 OASIS CODES: 208000, 208300, 208999 Disclaimer Odor Service Tips Types Of Odors, Their Sources And Treatments There are typically four (4) types of objectionable odors found in a vehicle, they are: ^ Chemical odors ^ Environmental odors ^ Microbiological odors ^ Human and other interior-generated odors Odors can be described in a number of ways: ^ Musty ^ Mildew Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors > Page 6127 ^ Fishy ^ Sweet ^ Burning ^ Chemical ^ Fuel ^ Oil ^ Exhaust ^ Wet cement ^ Urine ^ Tar ^ Fragrance ^ Body odor Chemical odors: ^ Coolant: sweet smell ^ Fuel: gasoline or diesel fuel smell ^ Oil: oil type or burning smell ^ Power Steering Fluid: oil type or burning smell ^ Transmission Fluid: oil type or burning smell ^ Washer Fluid: alcohol type smell ^ Gear Lube: garlic/sulphur smell ^ Refrigerant/Oil: ether type smell ^ Carpet/Trim Adhesives: fishy, urine, or sweet smell ^ Evaporator Core Coating: wet cement type smell Environmental odors: ^ Exhaust: exhaust, fuel, burning type smell ^ Industrial Pollutants: all types of smells ^ Dust: musty, mildew, wet cement type smell ^ Pollen: sweet smell ^ Tobacco: burning, tar smell Microbiological odors: Microbial growth supported by warm temperatures and moisture may occur on: ^ Foam Seals: musty, mildew smell ^ Rubber Seals: musty, mildew smell Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors > Page 6128 ^ Adhesives: musty, mildew smell ^ Standing Water: musty, mildew smell ^ Water Soaked Carpet/Trim: musty, mildew smell Human and other interior-generated odors: ^ Secretion From The Human Body: body odors ^ Perfuming Agents: sweet or fragrance smell ^ Dirty Clothes, Shoes, Socks: musty, mildew, body odors ^ Food/Beverage: sweet, musty, mildew, fishy smell The first step in diagnosing an odor concern is to verify the concern. To verify an odor you must determine when and under what circumstances the odor occurs and what type of odor it is. Chemical odors are usually constant regardless of A/C setting and can be enhanced by A/C system operation. Most chemical odors are caused by fluid leaks and some are caused by improperly cured carpet and trim adhesives or evaporator core coatings. Environmental odors usually occur for a short time and go away after the vehicle has passed through the affected area. These odors are usually only detected when a window is open or the A/C system is operating in a function that allows outside air to enter the vehicle. Microbiological odors, if in the A/C system, usually last for about 30 seconds when first turned on and will be detected in both Max and Normal A/C. Microbiological odors occurring elsewhere such as from standing water in doors or kick panels or wet carpeting may last indefinitely and will be more intense in Max A/C. Microbiological odors will not occur at temperatures below 50° F (10° C). Human and other interior-generated odors occur while the source is present and may linger for a short time after removal. These odors can be more noticeable during operation of the A/C system. They can be detected in the outside air position and may be more noticeable in recirculation mode. The first step in getting rid of odors is to find the source of the odor. Once the source is found, it must be removed and the affected area cleaned or treated. Chemical odors can be removed by repairing or replacing the component that causes the odor and then cleaning any residue that may have accumulated from the component failure. Environmental odors usually cannot be removed due to the fact that they occur from external sources and are an everyday occurrence. They can, however, be minimized by switching to Max A/C or recirculation mode. Microbiological odors can be eliminated by removing the source and then treating the affected area. Standing water must be allowed to drain and dry out. A/C systems may be treated by using Motorcraft A/C Cooling Coil Coating (YN-29), or equivalent meeting Ford specification (WSS-M99B187-A) as described in the Service Procedure in this article. Human and other interior-generated odors can be eliminated by removing the source and cleaning the affected area. A/C Odor Treatment Procedure 1. Try to reasonably rule out any other source for the odor. Check the carpet on the passenger side for signs of being wet. Continue diagnosis if water is found on carpet and repair as needed. Check the blower motor and cover for signs of moisture. This may be as a result of water bypassing the cowl baffling system that prevents rain intrusion. 2. Remove the engine side fasteners for the plenum cover. This will allow access to the Cowl Top Panel - Water RH. Remove this and inspect the air inlet screen. Use a shop vacuum if there is debris present. This debris may work its way into the evaporator case and act as food for the microbes to grow. Re-install the cowl components. 3. Check to see that the evaporator drain tube (or hose) is not plugged or restricted by debris. Clear anything that may be obstructing the drainage of water. 4. Open vehicle windows. 5. Disconnect A/C cycling switch electrical connector. 6. Set the following: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors > Page 6129 ^ Function selector switch in A/C mode ^ Temperature at full heat Blower at high speed ^ Engine running at normal operating temperature 7. Run vehicle (Steps 4-6 conditions) for 25 minutes. This will dry out the system. 8. Turn ignition off. 9. Disconnect and remove the blower motor and blower motor resistor by referring to Workshop Manual, Section 412-02 - Blower Motor. (This provides ease of access to the evaporator core and eliminates the possibility of contaminating the blower motor and/or blower motor resister with the Motorcraft A/C Cooling Coil Coating.) NOTE TO AVOID ANY POSSIBLE DAMAGE, DO NOT SPILL OR SPRAY THIS PRODUCT ON ANY INTERIOR SURFACE (E.G., INSTRUMENT PANEL) OR MATERIAL (E.G., CARPETING). 10. Add the full four (4) fluid ounces (1 bottle) of Motorcraft A/C Cooling Coil Coating (YN-29) to the Rotunda A/C Disodorizer Sprayer (Rotunda 164-R4700). For effective treatment, use the full four (4) fluid ounces on one vehicle application. Insert the A/C Disodorizer sprayer nozzle into the opening in the evaporator case and direct toward the face of the evaporator core. Spray Motorcraft A/C Cooling Coil Coating until empty. 11. Reinstall and reconnect blower motor resistor and blower motor. 12. Repeat Steps 6, 7, and 8 to cure the Cooling Coil Coating. 13. Reconnect A/C cycling switch. Air Inlet Vacuum Motor Bleed Valve Tee Installation 1. Remove the passenger front air bag. Refer to Workshop Manual Section 501-20B for procedure. 2. Disconnect vacuum line at air inlet door vacuum motor. Install bleed valve tee Part Number 3L8Z-19B888-AA into vacuum line 90 degree connector, and attach vacuum line with the vacuum bleed tee to air inlet door vacuum motor. Refer to Workshop Manual Section 412-04 (Vacuum Control Motor - Outside Air Inlet) for component location. 3. Follow Workshop Manual procedures for reinstalling passenger front air bag. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors Technical Service Bulletin # 03-5-6 Date: 030317 A/C - Musty or Mildew Type Odors Article No. 03-5-6 03/17/03 CLIMATE CONTROL - MUSTY OR MILDEW TYPE ODOR FROM CLIMATE CONTROL SYSTEM FORD: 2001-2003 ESCAPE ISSUE Some vehicles may exhibit a musty and/or mildew type odor coming from the climate control system. This odor is caused by mildew-type fungi growth in the A/C evaporator. It is most noticeable when the A/C is first turned on. ACTION Apply Motorcraft A/C Cooling Coil Coating to the A/C system, which encapsulates the mildew to help reduce odors. Install air inlet vacuum motor bleed valve, which operates the recirculation/fresh air door to default to fresh mode when the vehicle is parked to dry out the evaporator core. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030506A Apply Motorcraft A/C 1.5 Hrs. Cooling Coil Coating To The A/C System Then Install Air Inlet Vacuum Motor Bleed Valve DEALER CODING CONDITION BASIC PART NO. CODE 19B55 53 OASIS CODES: 208000, 208300, 208999 Disclaimer Odor Service Tips Types Of Odors, Their Sources And Treatments There are typically four (4) types of objectionable odors found in a vehicle, they are: ^ Chemical odors ^ Environmental odors ^ Microbiological odors ^ Human and other interior-generated odors Odors can be described in a number of ways: ^ Musty ^ Mildew Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors > Page 6135 ^ Fishy ^ Sweet ^ Burning ^ Chemical ^ Fuel ^ Oil ^ Exhaust ^ Wet cement ^ Urine ^ Tar ^ Fragrance ^ Body odor Chemical odors: ^ Coolant: sweet smell ^ Fuel: gasoline or diesel fuel smell ^ Oil: oil type or burning smell ^ Power Steering Fluid: oil type or burning smell ^ Transmission Fluid: oil type or burning smell ^ Washer Fluid: alcohol type smell ^ Gear Lube: garlic/sulphur smell ^ Refrigerant/Oil: ether type smell ^ Carpet/Trim Adhesives: fishy, urine, or sweet smell ^ Evaporator Core Coating: wet cement type smell Environmental odors: ^ Exhaust: exhaust, fuel, burning type smell ^ Industrial Pollutants: all types of smells ^ Dust: musty, mildew, wet cement type smell ^ Pollen: sweet smell ^ Tobacco: burning, tar smell Microbiological odors: Microbial growth supported by warm temperatures and moisture may occur on: ^ Foam Seals: musty, mildew smell ^ Rubber Seals: musty, mildew smell Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors > Page 6136 ^ Adhesives: musty, mildew smell ^ Standing Water: musty, mildew smell ^ Water Soaked Carpet/Trim: musty, mildew smell Human and other interior-generated odors: ^ Secretion From The Human Body: body odors ^ Perfuming Agents: sweet or fragrance smell ^ Dirty Clothes, Shoes, Socks: musty, mildew, body odors ^ Food/Beverage: sweet, musty, mildew, fishy smell The first step in diagnosing an odor concern is to verify the concern. To verify an odor you must determine when and under what circumstances the odor occurs and what type of odor it is. Chemical odors are usually constant regardless of A/C setting and can be enhanced by A/C system operation. Most chemical odors are caused by fluid leaks and some are caused by improperly cured carpet and trim adhesives or evaporator core coatings. Environmental odors usually occur for a short time and go away after the vehicle has passed through the affected area. These odors are usually only detected when a window is open or the A/C system is operating in a function that allows outside air to enter the vehicle. Microbiological odors, if in the A/C system, usually last for about 30 seconds when first turned on and will be detected in both Max and Normal A/C. Microbiological odors occurring elsewhere such as from standing water in doors or kick panels or wet carpeting may last indefinitely and will be more intense in Max A/C. Microbiological odors will not occur at temperatures below 50° F (10° C). Human and other interior-generated odors occur while the source is present and may linger for a short time after removal. These odors can be more noticeable during operation of the A/C system. They can be detected in the outside air position and may be more noticeable in recirculation mode. The first step in getting rid of odors is to find the source of the odor. Once the source is found, it must be removed and the affected area cleaned or treated. Chemical odors can be removed by repairing or replacing the component that causes the odor and then cleaning any residue that may have accumulated from the component failure. Environmental odors usually cannot be removed due to the fact that they occur from external sources and are an everyday occurrence. They can, however, be minimized by switching to Max A/C or recirculation mode. Microbiological odors can be eliminated by removing the source and then treating the affected area. Standing water must be allowed to drain and dry out. A/C systems may be treated by using Motorcraft A/C Cooling Coil Coating (YN-29), or equivalent meeting Ford specification (WSS-M99B187-A) as described in the Service Procedure in this article. Human and other interior-generated odors can be eliminated by removing the source and cleaning the affected area. A/C Odor Treatment Procedure 1. Try to reasonably rule out any other source for the odor. Check the carpet on the passenger side for signs of being wet. Continue diagnosis if water is found on carpet and repair as needed. Check the blower motor and cover for signs of moisture. This may be as a result of water bypassing the cowl baffling system that prevents rain intrusion. 2. Remove the engine side fasteners for the plenum cover. This will allow access to the Cowl Top Panel - Water RH. Remove this and inspect the air inlet screen. Use a shop vacuum if there is debris present. This debris may work its way into the evaporator case and act as food for the microbes to grow. Re-install the cowl components. 3. Check to see that the evaporator drain tube (or hose) is not plugged or restricted by debris. Clear anything that may be obstructing the drainage of water. 4. Open vehicle windows. 5. Disconnect A/C cycling switch electrical connector. 6. Set the following: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 03-5-6 > Mar > 03 > A/C - Musty or Mildew Type Odors > Page 6137 ^ Function selector switch in A/C mode ^ Temperature at full heat Blower at high speed ^ Engine running at normal operating temperature 7. Run vehicle (Steps 4-6 conditions) for 25 minutes. This will dry out the system. 8. Turn ignition off. 9. Disconnect and remove the blower motor and blower motor resistor by referring to Workshop Manual, Section 412-02 - Blower Motor. (This provides ease of access to the evaporator core and eliminates the possibility of contaminating the blower motor and/or blower motor resister with the Motorcraft A/C Cooling Coil Coating.) NOTE TO AVOID ANY POSSIBLE DAMAGE, DO NOT SPILL OR SPRAY THIS PRODUCT ON ANY INTERIOR SURFACE (E.G., INSTRUMENT PANEL) OR MATERIAL (E.G., CARPETING). 10. Add the full four (4) fluid ounces (1 bottle) of Motorcraft A/C Cooling Coil Coating (YN-29) to the Rotunda A/C Disodorizer Sprayer (Rotunda 164-R4700). For effective treatment, use the full four (4) fluid ounces on one vehicle application. Insert the A/C Disodorizer sprayer nozzle into the opening in the evaporator case and direct toward the face of the evaporator core. Spray Motorcraft A/C Cooling Coil Coating until empty. 11. Reinstall and reconnect blower motor resistor and blower motor. 12. Repeat Steps 6, 7, and 8 to cure the Cooling Coil Coating. 13. Reconnect A/C cycling switch. Air Inlet Vacuum Motor Bleed Valve Tee Installation 1. Remove the passenger front air bag. Refer to Workshop Manual Section 501-20B for procedure. 2. Disconnect vacuum line at air inlet door vacuum motor. Install bleed valve tee Part Number 3L8Z-19B888-AA into vacuum line 90 degree connector, and attach vacuum line with the vacuum bleed tee to air inlet door vacuum motor. Refer to Workshop Manual Section 412-04 (Vacuum Control Motor - Outside Air Inlet) for component location. 3. Follow Workshop Manual procedures for reinstalling passenger front air bag. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6138 Evaporator Core: Description and Operation NOTE: Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C component or damage to the suction accumulator. The A/C evaporator housing contains the A/C evaporator core. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. ^ A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first four plate/fin sections. ^ The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. ^ The next five plate/fin sections are partitioned to force the refrigerant to flow toward the bottom of the A/C evaporator core. ^ Refrigerant then continues through to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. ^ This W-pass flow pattern transfers the flow of refrigerant and oil through the A/C evaporator core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6139 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45-minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. ^ If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. ^ If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. ^ If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6140 Evaporator Core: Service and Repair REMOVAL NOTE: ^ Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C component or damage to the suction accumulator. ^ If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. ^ The evaporator core and evaporator housing must be installed as a complete unit. 1. Remove the A/C evaporator core housing. 2. Transfer, the components from the old evaporator core housing to the new evaporator core housing. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the new A/C evaporator core with the correct amount of PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service Precautions Expansion Block/Orifice Tube: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service Precautions > Page 6144 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: Install a new A/C evaporator core orifice whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: ^ color-coded green ^ an orifice diameter of 1.25 mm (0.052 inch) ^ located in the condenser to evaporator line ^ Changes the high-pressure liquid refrigerant into a low-pressure liquid. ^ filter screens located on the inlet and outlet ends of the orifice body ^ The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. ^ O-ring seals on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. ^ Adjustment or repair cannot be made to the A/C evaporator core orifice. A new A/C evaporator core orifice must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service Precautions > Page 6145 Expansion Block/Orifice Tube: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Disconnect the condenser to evaporator line at the orifice tube. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 2. Engage the special tool onto the A/C evaporator core orifice. 3. Hold the special tool T-handle stationary and rotate the special tool body to remove the A/C evaporator core orifice. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service Precautions > Page 6146 4. If the A/C evaporator core orifice is broken, screw the end of the special tool into the broken A/C evaporator core orifice. 5. Hold the special tool T-handle stationary and rotate the special tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. ^ Use PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the special tool. 3. Using the special tool, insert the A/C evaporator core orifice into the condenser to evaporator line until seated. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service Precautions > Page 6147 4. Remove the special tool. 5. Connect the condenser to evaporator line at the orifice tube. 6. Recharge the A/C system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service Precautions > Page 6148 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6157 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6158 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6164 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6165 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Technician Safety Information Heater Core: Technician Safety Information WARNING: ^ CARBON MONOXIDE GAS IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Technician Safety Information > Page 6168 Heater Core: Vehicle Damage Warnings CAUTION: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6169 Heater Core: Description and Operation Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the heater core housing. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6170 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE GAS IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the Plugged Heater Core Component Test before the Heater Core Pressure Test. Carry out a system inspection by checking the heater system thoroughly. CAUTION: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. 2. Check the integrity of the heater water hose clamps. Heater Core - Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: ^ the heater core may have an air pocket. ^ the heater core may be plugged, or ^ the thermostat is not working correctly. Heater Core - Pressure Test Use the radiator/heater core pressure tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6171 tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service Precautions > Page 6172 Heater Core: Service and Repair REMOVAL 1. Drain the engine coolant. NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. 2. Disconnect the heater hoses from the heater core. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Remove the heater blending door levers. 1 Remove the screw for heater blending door. 2 Remove the levers for the blending door. 5. Remove the heater core. 1 Remove the three screws. 2 Remove the cover for the heater core and pull the heater core out of the housing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Before installing the temperature control cable, make sure the blend door, cable and temperature switch are correctly positioned. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Description and Operation Heater Core Case: Description and Operation The heater core housing contains the following components: ^ heater core ^ air temperature control door ^ panel air flow control door ^ defrost/floor air flow control door Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Description and Operation > Page 6176 Heater Core Case: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. If equipped with A/C, remove the A/C evaporator core housing. 5. Remove the heater core housing. 1 Remove the heater core housing retaining nuts. 2 Carefully remove the heater core housing to avoid spilling engine coolant in the passenger area. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6185 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6186 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6192 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 6193 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 6194 Heater Hose: Service and Repair REMOVAL 1. Drain the engine coolant. 2. Disconnect the heater hoses from the heater core. 3. Disconnect the heater hose from the hose connection. 4. Remove the RH front wheel. 5. Disconnect the heater hose from the hose connection. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the hoses with Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: ^ relieve unusually high refrigerant system discharge pressure buildups of (3,792 kPa [550 psi] and above). ^ prevent damage to the A/C compressor and other system components. ^ avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 6198 High Pressure Safety Valve HVAC: Service and Repair REMOVAL 1. Recover the refrigerant. 2. Raise and support the vehicle. 3. Remove the RH splash shield. 4. If equipped, disconnect the engine block heater electrical connector. 5. Remove the A/C compressor pressure relief valve. NOTE: Vehicles with the 2.0L Zetec engine shown, vehicles with the 3.0L (4V) engine similar. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions CAUTION: Plug all ports to prevent contamination from dirt or moisture. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Page 6202 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator line contains high-pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube assembly is attached to the A/C compressor with O-ring seals. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Page 6203 Hose/Line HVAC: Service and Repair REMOVAL 1. Remove the A/C pressure cut-off switch. 2. Remove the evaporator core orifice. 3. Disconnect the condenser to evaporator line from the A/C evaporator core. CAUTION: Plug all ports to prevent contamination from dirt or moisture. 4. Remove the evaporator line support nut and remove the line from the A/C evaporator core. 5. Remove the front bumper cover. 6. Remove the nut and disconnect the condenser to evaporator line from the A/C condenser core and remove the condenser to evaporator line. CAUTION: Plug all ports to prevent contamination from dirt or moisture. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refregerant Capacity Refregerant Capacity 1 lbs 14 oz (850 kg) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6208 Refrigerant: Fluid Type Specifications A/C Refrigerant A/C Refrigerant R-134a Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6209 Refrigerant: Service Precautions CAUTION: ^ Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. 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. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. ^ If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection Refrigerant: Testing and Inspection Electronic Leak Detection Refrigerent Leak Detector SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. 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. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow instructions included with leak detector for handling and operation techniques. NOTE: System pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 2. If a leak is found, recover the refrigerant and repair the system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 6212 Refrigerant: Testing and Inspection Tracer Dye Leak Detection Special Tool(s) SPECIAL TOOL(S) NOTE: Ford Motor Company vehicles are produced with R-134a Leak Tracer Dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. 1. Check for leaks using a 120-watt UV spot lamp. 2. Scan all components, fittings and lines of the A/C system. 3. After the leak is repaired, remove any traces of leak dye with a general purpose oil solvent. 4. Verify the repair by operating the system for a short time and inspecting with the UV spot lamp. Tracer Dye Injection NOTE: System pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 1. Install the Manifold Gauge Set or a recovery station. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 6213 2. Turn the valve on the fluorescent tracer dye injector all the way to the left to close the valve. 3. Fill the reservoir with 7 ml (0.25 ounce) of R-134a Fluorescent Tracer Dye 164-R3712. 4. Install the injector between the low-side quick disconnect and the vehicle low-pressure service gauge port valve. 5. Open all quick disconnect valves and charge the refrigerant system. 6. When system charging is complete, recover the refrigerant from the dye injector. 7. Remove the dye injector from the low-side quick disconnect valve. NOTE: Only connect the dye-injector to the Manifold Gauge Set or the charging/recovery station when dye is to be injected. The dye injector has a one-way check valve that will prevent system refrigerant recovery and evacuation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery Refrigerant: Service and Repair Discharging and Recovery Special Tool(s) SPECIAL TOOL(S) 1. Prior to recovering or charging the refrigerant system, you must verify the purity of the refrigerant. 2. Connect the R-134a A/C Refrigerant Center to the low and high pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 6. If the system pressure rises, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs, then evacuate and recharge the A/C system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 6216 Refrigerant: Service and Repair Identifying Refrigerants Delux A/C Refrigerant Analyzer SPECIAL TOOL(S) 1. Follow the instructions included with the refrigerant analyzer to obtain the sample for testing. NOTE: Prior to recovering or charging the refrigerant system, you must use an A/C refrigerant analyzer to identify gas samples taken directly from the refrigeration system or storage containers. 2. The analyzer will display one of the following: ^ A green "PASS" Light Emitting Diode (LED) will light if the purity of the R-134, R-12 or the R-22 is better than 98% by weight. ^ A red "FAIL" LED will light if the purity of the gases does not meet the 98% purity standard. ^ A red "FAIL" LED and "HYDROCARBON" light will illuminate and a horn will sound if a hydrocarbon is detected above 5%. This will alert the user of potential hazards. 3. If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 6217 Refrigerant: Service and Repair Handling of Contaminated Refrigerants 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. ^ This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. ^ If this equipment is not available, contact an A/C service facility in your area with the correct equipment to carry out this service. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. 2. Determine and correct the cause of the customer's initial concern. 3. Remove the suction accumulator/drier. NOTE: ^ Residual refrigerant oil in the suction accumulator/drier must be drained and measured for correct oil system matching. ^ The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. 4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8. Dispose of contaminated refrigerant according to all federal, state and local regulations. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Discharging and Recovery > Page 6218 Refrigerant: Service and Repair Air Conditioning (A/C) System Evacuation and Charging Special Tool(s) SPECIAL TOOL(S) 1. Prior to charging the refrigerant system, you must verify the purity of the refrigerant. 2. Connect the R-134a A/C Refrigerant Center to the low and high pressure service gauge port valves. NOTE: Ford Motor Company recommends use of a charging station to carry out evacuation and charging of the refrigerant system. If a charging station is not available, system charging may be accomplished using a separate vacuum pump, charging cylinder, and manifold gauge set. 3. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) (vacuum) and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 4. Turn off the evacuation pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leaks, and evacuate the system again. 5. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. 6. Charge the system with the specified weight of refrigerant and refrigerant oil. 7. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the suction pressure drops to approximately 207 kPa (30 psi), close the charging hose valve. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 6219 Refrigerant: Tools and Equipment Refrigerent Leak Detector Special Tool(s) Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 6220 Delux A/C Refrigerant Analyzer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity Refrigerant Oil Capacity 9 oz (266 ml) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6225 Refrigerant Oil: Fluid Type Specifications A/C Oil A/C Oil PAG Refrigerant Compressor Oil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6226 Refrigerant Oil: Service Precautions CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6227 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDITION CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. ^ If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. ^ Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6228 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: ^ installation of a new A/C evaporator core orifice ^ installation of a new A/C compressor pressure relief valve ^ installation of a new refrigerant line ^ repair of an O-ring seal leak ^ repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C Clutch Cycling Pressure Switch View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C Clutch Cycling Pressure Switch > Page 6233 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 6236 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6237 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). ^ The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). ^ When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the Powertrain Control Module (PCM) which energizes the A/C relay and supplies B+ voltage to the A/C clutch field coil. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. A/C Pressure Cut-Off Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the condenser to evaporator line. ^ A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, is used to monitor the compressor discharge pressure. ^ It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. ^ The A/C pressure cut-off switch has two sets of contacts. One electrical contact is normally closed. ^ When the compressor discharge pressure rises to approximately 3,103 kPa (450 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. The switch contains a second set of electrical contacts used for high-speed fan control. ^ When the compressor discharge pressure reaches approximately 2,241 kPa (325 psi), these contacts close and engage the high-speed fan control. ^ When the pressure drops to approximately 1,896 kPa (275 psi), the contacts again open and the high speed fan control is disengaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Cycling Switch REMOVAL 1. Remove the A/C cycling switch. 1 Disconnect the A/C cycling switch electrical connector. 2 Remove the A/C cycling switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch > Page 6240 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff Switch REMOVAL 1. Remove the pressure cut-off switch. 1 Disconnect the A/C pressure cut-off switch electrical connector. 2 Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6245 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6246 Blower Motor Relay: Description and Operation The blower motor relay supplies voltage to the blower motor and is activated when the key is ON and the function selector switch is in any position besides OFF. The blower motor relay is located under the instrument panel next to the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6247 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6248 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6252 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6253 Compressor Clutch Relay: Description and Operation The A/C compressor clutch relay supplies voltage to the A/C compressor clutch and is located in the Battery Junction Box (BJB). The Power Control Module (PCM) can interrupt the A/C compressor operation through the A/C compressor clutch relay under the following conditions: ^ during engine start-up ^ Wide Open Throttle (WOT) ^ low engine idle conditions ^ excessively high engine temperatures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6254 Compressor Clutch Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6255 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair Blower Motor Switch: Service and Repair REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the blower motor switch knob. 3. Remove the blower motor switch. ^ Depress the locking tab. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C Clutch Cycling Pressure Switch View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > A/C Clutch Cycling Pressure Switch > Page 6264 View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 6267 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6268 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). ^ The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). ^ When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the Powertrain Control Module (PCM) which energizes the A/C relay and supplies B+ voltage to the A/C clutch field coil. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. A/C Pressure Cut-Off Switch The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the condenser to evaporator line. ^ A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, is used to monitor the compressor discharge pressure. ^ It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. ^ The A/C pressure cut-off switch has two sets of contacts. One electrical contact is normally closed. ^ When the compressor discharge pressure rises to approximately 3,103 kPa (450 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. The switch contains a second set of electrical contacts used for high-speed fan control. ^ When the compressor discharge pressure reaches approximately 2,241 kPa (325 psi), these contacts close and engage the high-speed fan control. ^ When the pressure drops to approximately 1,896 kPa (275 psi), the contacts again open and the high speed fan control is disengaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Cycling Switch REMOVAL 1. Remove the A/C cycling switch. 1 Disconnect the A/C cycling switch electrical connector. 2 Remove the A/C cycling switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning (A/C) Cycling Switch > Page 6271 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff Switch REMOVAL 1. Remove the pressure cut-off switch. 1 Disconnect the A/C pressure cut-off switch electrical connector. 2 Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System, Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6275 Clutch Cycling Orifice Tube Type Refrigerant System, Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6276 Clutch Cycling Orifice Tube Type Refrigerant System, Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6277 Clutch Cycling Orifice Tube Type Refrigerant System, Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 6278 Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure gauge port valve is located on the condenser to evaporator line. The low-pressure gauge port valve is located on the A/C manifold and tube assembly. The fitting is an integral part of the refrigeration line or component. ^ Special couplings are required for both the high-side and low-side gauge ports. ^ The Schrader-type valve core can be repaired if the seal leaks. ^ Always install the A/C charging valve cap on the gauge port valves after repairing the refrigerant system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions Vacuum Harness HVAC: Service Precautions WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 6282 Vacuum Harness HVAC: Service and Repair Vacuum Tester Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 3 mm (0.125 inch) inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (0.375 inch) into the ends of the standard 3 mm (0.125 inch) service vacuum hose section. 6. Shake the service joint after assembly to make sure the O-ring seal solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. ^ Use the Vacuum Tester or equivalent. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 6283 Vacuum Tester Kit Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat mounting points Safety belts, safety belt buckles and safety belt retractors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 6289 SRS wiring, wiring harnesses and connectors 7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 6290 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision 1. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS, IF SO EQUIPPED, CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE CORRECTLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6297 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6298 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6299 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6300 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6301 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6302 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 6307 View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 6308 View 151-19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 6311 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 6312 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Side Air Bag Module, Left > Page 6313 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Technician Safety Information Air Bag: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE. ^ FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 6316 Air Bag: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. ^ When positioning the seat or separating/installing the seat bottom from the back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. ^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. ^ Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Page 6317 Air Bag: Description and Operation Air Bag Module - Driver NOTE: References to the driver air bag module must not be confused with the seat-mounted air bag components of the Supplemental Restraint System (SRS). The driver air bag module: ^ is steering wheel mounted. ^ will deploy upon receiving a signal from the Restraints Control Module (RCM). ^ has no subassemblies. ^ is serviced with the steering wheel as an assembly. Air Bag Module - Driver Side NOTE: ^ References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the supplemental restraint system (SRS). ^ When installing a new side air bag module after deployment, refer to Seats for additional information. The driver side air bag module: ^ will deploy upon receiving a signal from the restraints control module (RCM) initiated by the driver side crash sensor. ^ is installed as an assembly. ^ is mounted in the driver seat back. Air Bag Module - Passenger NOTE: References to the passenger air bag module must not be confused with the seat-mounted air bag components of the supplemental restraint system (SRS). The passenger air bag module: ^ has no separately repairable parts and is installed as an assembly. ^ is mounted in the RH side of the instrument panel. Air Bag Module - Passenger Side NOTE: ^ References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the supplemental restraint system (SRS). ^ When installing a new side air bag module after deployment, refer to Seats. The passenger side air bag module: ^ will deploy upon receiving a signal from the restraints control module (RCM) initiated by the passenger side crash sensor. ^ is installed as an assembly. ^ is mounted in the passenger seat back. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module Air Bag: Service and Repair Driver Air Bag Module Removal and Installation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be installed new, not repainted. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Depower the system. See: Air Bag(s) Arming and Disarming/Service and Repair/Air Bag Disarming and Arming/Depowering and Repowering Procedure 2. NOTE: The driver air bag module and steering wheel must be serviced as an assembly. These components are not serviced separately NOTE: Make sure to follow all steps and instructions in the removal of the steering wheel. Remove the steering wheel. 3. To install, reverse the removal procedure. 4. Repower the system. See: Air Bag(s) Arming and Disarming/Service and Repair/Air Bag Disarming and Arming/Depowering and Repowering Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6320 Air Bag: Service and Repair Passenger Air Bag Module With Side Air Bags Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6321 ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove box past its stops. 3. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6322 4. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. 5. Remove the steering wheel access cover. 6. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6323 8. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6324 12. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 14. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6325 18. Disconnect the battery ground cable and wait at least one minute. 19. Remove the four passenger air bag module bolts. 20. Reaching one hand into the glove box opening, push outward on the passenger air bag module and remove it from the instrument panel. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6326 TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Make sure the J-clips are correctly aligned to the holes in the passenger air bag module before positioning it in the instrument panel. 2. Position and align the two passenger air bag module trim cover alignment pins (one shown) to the instrument panel openings. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6327 3. Install the passenger air bag module trim cover into the instrument panel. ^ Install the trim cover alignment pins into the instrument panel. ^ When aligned correctly, the passenger air bag module trim cover will have an even gap around its perimeter and sit flat up against the instrument panel. 4. Install the bolts. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Connect the passenger air bag module electrical connector. 7. Close the glove box. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6328 8. Connect the battery ground cable. 9. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 10. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 11. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Connect the driver air bag module electrical connector. 13. Install the steering wheel access cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6329 14. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. 16. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6330 17. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 18. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 19. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 20. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6331 21. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 22. Connect the battery ground cable. 23. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bags Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6332 AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Open the glove box past its stops. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6333 3. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 4. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. 5. Remove the steering wheel access cover. 6. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6334 7. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 8. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 10. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6335 11. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 12. Connect the battery ground cable. 13. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 14. Disconnect the battery ground cable and wait at least one minute. 15. Remove the four passenger air bag module bolts. 16. Reaching one hand into the glove box opening, push outward on the passenger air bag module and remove it from the instrument panel. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6336 REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Make sure the J-clips are correctly aligned to the holes in the passenger air bag module before positioning it in the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6337 2. Position and align the two passenger air bag module trim cover alignment pins (one shown) to the instrument panel openings. 3. Install the passenger air bag module trim cover into the instrument panel. ^ Install the trim cover alignment pins into the instrument panel. ^ When aligned correctly, the passenger air bag module trim cover will have an even gap around its perimeter and sit flat up against the instrument panel. 4. Install the bolts. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6338 6. Connect the passenger air bag module electrical connector. 7. Close the glove box. 8. Connect the battery ground cable. 9. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 10. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 11. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6339 12. Connect the driver air bag module electrical connector. 13. Install the steering wheel access cover. 14. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6340 16. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 17. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6341 Air Bag: Service and Repair Side Air Bag Module Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6342 ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ If a side air bag deployment took place the seatback pad, trim cover, and side air bag module must be replaced. The seatback frame should be replaced if necessary. ^ When replacing the side air bag after deployment, refer to Seats concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the affected seat from the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES, AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 3. Pry out and remove the seat cushion adjuster handle center plug. NOTE: ^ Use care not to damage the center hole plug. ^ The driver side air bag module removal is shown, the passenger side air bag module removal is similar. 4. Remove the seat cushion adjuster handle. 1 Release the retaining tabs. 2 Pull and remove the seat cushion adjuster handle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6343 5. Remove the outboard seat cushion side shield. 1 Remove the seat backrest lever cover. 2 Remove the screw. 3 Pull out to release the retaining clips and remove the seat cushion side shield. ^ If equipped, disconnect the power seat switch electrical connector. 6. Remove the inboard seat cushion side shield. ^ Pull out to release the retaining clips. 7. Release the pin-type retainers and separate the side air bag electrical connector and wire harness from the seat. NOTE: Note the wire harness routing for installation. 8. Remove the seat backrest pivot nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6344 9. Remove the seat backrest. 1 Remove the seat backrest bolts. 2 Slide the seat backrest pivot stud out of the seat cushion frame and remove the seat backrest. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. 10. Turn the manual lumbar handle clockwise until it stops, releasing all tension on the manual lumbar support cable. 11. Pull and remove the manual lumbar support adjustment handle. 12. Separate the seat backrest trim cover J-retainers. 13. Remove the seat backrest trim cover. 1 Placing a hand between the seat backrest trim cover and pad, carefully separate the hook and loop strips. 2 Roll up the seat back trim cover, in an inside out fashion, and remove the seat backrest trim cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6345 WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 14. Remove the seat backrest pad from the frame. 15. Separate the side air bag module wiring harness pin-type retainers from the seat back frame. 16. Remove the side air bag module. 1 Remove the nuts. 2 Remove the side air bag module. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6346 GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ When replacing the side air bag after deployment, refer to Seats concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side air bag module onto the seat backrest frame mounting bracket. 1 Position the side air bag module to the seat backrest frame mounting bracket. 2 Install the nuts. NOTE: The driver side air bag module installation is shown, the passenger side air bag module installation is similar. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6347 AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. 2. Route the side air bag module wire harness. Install the pin-type retainers to the seat backrest frame. 3. Position the seat backrest pad onto the seat backrest frame. WARNING: INSPECT THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. 4. Install the seat backrest trim cover. 1 Position and roll the seat backrest trim cover down over the seat backrest frame and pad. 2 Attach the hook and loop strips. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6348 5. Attach the seat back trim cover J-retainers. 6. Install the manual lumbar control knob. 7. Install the seat backrest bolts. 1 Align the seat backrest to the seat bottom. 2 Install the seat backrest bolts. CAUTION: When positioning the seat or installing the seat bottom to the seat back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. 8. Install the pivot nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6349 9. Route the side air bag module wire harness as noted in removal. Install the wire harness and electrical connector pin-type retainers. 10. Install the outboard seat cushion side shield. 1 Align the retaining clips and push inward, seating the retaining clips. ^ If equipped, connect the power seat switch electrical connector. 2 Install the screw. 3 Install the seat backrest lever cover. 11. Install the seat cushion adjuster handle. 12. Install the seat cushion adjuster handle center plug. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6350 13. Align the retaining clips and push inward, installing the inboard seat cushion side shield. 14. Install the affected seat into the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 15. Connect the battery ground cable. 16. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 17. Check the active restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Page 6351 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6355 Air Bag Control Module: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 6358 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 6359 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash ^ monitors the air bag Supplemental Restraint System (SRS) for faults ^ illuminates the air bag indicator if a fault is detected ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs) ^ signals the instrument cluster to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 6360 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6363 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6364 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the instrument panel, disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6365 8. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 10. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6366 12. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 13. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 14. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6367 18. Disconnect the battery ground cable and wait at least one minute. 19. Position the carpet back at the right-hand side of the center tunnel area under the instrument panel. 20. Remove the right-hand side restraint control module (RCM) retaining bolts. 21. Remove the lower LH center instrument panel finish panel. 22. Position the carpet back at the left-hand side of the center tunnel area under the instrument panel. 23. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking dips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6368 INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6369 2. Tighten the right-hand side RCM bolts. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Reposition the carpet back at the right-hand side of the center tunnel area under the instrument panel. 4. Connect the RCM. 1 Tighten the bolt. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 5. Reposition the carpet back at the left-hand side of the center tunnel area under the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6370 6. Install the lower LH center instrument panel finish panel. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6371 12. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6372 onto the bracket under the seat. 16. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 17. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6373 19. Connect the passenger air bag module electrical connector. 20. Close the glove box. 21. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver air bag module electrical connector. 23. Install the steering wheel access cover. 24. Connect the battery ground cable. 25. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6374 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6375 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6376 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the instrument panel, disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6377 8. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 12. Connect the battery ground cable. 13. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6378 14. Disconnect the battery ground cable and wait at least one minute. 15. Position the carpet back at the right-hand side of the center tunnel area under the instrument panel. 16. Remove the right-hand side restraint control module (RCM) retaining bolts. 17. Remove the lower LH center instrument panel finish panel. 18. Position the carpet back at the left-hand side of the center tunnel area under the instrument panel. 19. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking dips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6379 INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6380 2. Tighten the right-hand side RCM bolts. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Reposition the carpet back at the right-hand side of the center tunnel area under the instrument panel. 4. Connect the RCM. 1 Tighten the bolt. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 5. Reposition the carpet back at the left-hand side of the center tunnel area under the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6381 6. Install the lower LH center instrument panel finish panel. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6382 12. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6383 15. Connect the passenger air bag module electrical connector. 16. Close the glove box. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the driver air bag module electrical connector. 19. Install the steering wheel access cover. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6384 Air Bag Control Module: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts according to this procedure. Weld nuts must be installed according to Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restr.Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts according to Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6385 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Page 6386 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Technician Safety Information Clockspring Assembly / Spiral Cable: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES, AND INSTRUCTIONS IN THE STEERING WHEEL REMOVAL AND INSTALLATION PROCEDURE. ^ 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. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 6392 Clockspring Assembly / Spiral Cable: Vehicle Damage Warnings CAUTION: ^ Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. ^ Make sure the road wheels are in the straight ahead position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6393 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring: ^ is mounted on the steering column, behind the steering wheel. ^ provides a continuous electrical path between the Restraints Control Module (RCM) and the driver air bag module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6394 Clockspring Assembly / Spiral Cable: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6395 be deactivated. ^ Restraint system diagnostic tool MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat Systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Make sure the wheels are in the straight-ahead position. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the steering wheel. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES, AND INSTRUCTIONS IN THE STEERING WHEEL REMOVAL AND INSTALLATION PROCEDURE. Vehicles with tilt column 4. Position the steering column completely downward. All vehicles 5. Push in where indicated, releasing the retaining tabs, and remove the upper steering column shroud. 6. Remove the lower steering column shroud. 1 Release the tilt column locking lever, if equipped. 2 Remove the three screws. 3 Remove the lower steering column shroud. NOTE: The steering column must be in the raised position, with the tilt column lever released (if equipped), to remove the lower steering column shroud. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6396 7. Apply two strips of masking tape across the clockspring to prevent accidental rotation when the clockspring is removed. 8. Separate the clockspring from the steering column. 1 Remove the screws. 2 Pull out and separate the clockspring from the steering column. 9. Remove the clockspring. 1 Disconnect the accessory electrical connector. 2 Push to release the clockspring electrical connector locking clip. 3 With the clockspring electrical connector locking clip in the released position, pull and disconnect the clockspring electrical connector. 4 Remove the clockspring. 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the steering column. INSTALLATION WARNING: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6397 ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Connect the battery ground cable. 2. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 3. Disconnect the battery ground cable and wait at least one minute. Vehicles receiving a new clockspring 4. Remove the key from the clockspring, holding the rotor in its centralized position. ^ Do not allow the clockspring rotor to turn from this position. NOTE: A new clockspring is supplied in a centralized position and held there with a key. Vehicles needing clockspring recentering Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6398 5. Centralize the clockspring. 1. Hold the clockspring outer housing stationary. 2. While turning the rotor clockwise, carefully feel for the ribbon wire to run out of length, and a slight resistance is felt. Stop turning at this point. CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. 3. Turn the rotor counterclockwise approximately 2-3/4 turns. This is the center point of the clockspring. ^ Do not allow the rotor to turn from this position. 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. CAUTION: Make sure the road wheels are in the straight ahead position. NOTE: If a clockspring has rotated out of center, follow through with this step. All vehicles 6. Make sure the road wheels are in the straight ahead position. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the steering column. 8. Connect the clockspring electrical connectors. 1 Connect the clockspring electrical connector. 2 Connect the accessory electrical connector. NOTE: Recenter clockspring as needed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6399 Vehicle repairs reusing the same clockspring 9. Remove the tape applied during clockspring removal. NOTE: When the tape is removed, do not allow the clockspring to turn. All vehicles 10. Align the clockspring for installation. ^ Align the large slot to the large tab in the clockspring. ^ Align the small slot to the small tab in the clockspring. NOTE: The clockspring is shown from the back for clarity. 11. Install the clockspring. 1 With the slots and tabs aligned, slide the clockspring over the steering column. 2 With the clockspring sitting flush against the multi-function switch, install the screws. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6400 12. Install the lower steering column shroud. 1 Release the tilt column locking lever, if equipped. 2 Position the lower steering column shroud to the steering column. NOTE: The steering column must be in the raised position, with the tilt column lever released (if equipped), to install the lower steering column shroud. 3 Install the three screws. Vehicles with tilt column 13. Position the steering column completely downward. All vehicles 14. Position the upper steering column shroud to the steering column and completely engage the retaining tabs. ^ Make sure the upper steering column shroud is aligned correctly and the retaining tabs are completely engaged. 15. Install the steering wheel. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES, AND INSTRUCTIONS IN THE STEERING WHEEL REMOVAL AND INSTALLATION PROCEDURE. 16. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6401 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left > Page 6406 View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Right Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Right > Page 6409 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 6412 Impact Sensor: Technician Safety Information WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Page 6413 Impact Sensor: Description and Operation WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. For this vehicle, the SRS employs three crash sensors. One of the sensors is integral to the RCM and is not serviceable separately. In addition, there are two side crash sensors located in the LH and RH B-pillars. The RCM is mounted on the center tunnel under the instrument panel. Mounting orientation is critical for correct operation of all crash sensors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6416 be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR, TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6417 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6418 8. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 10. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6419 12. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 14. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 18. Disconnect the battery ground cable and wait at least one minute. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6420 19. Remove the B-pillar trim panel. 20. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6421 seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side crash sensor. 1 Position the side crash sensor to the B-pillar. 2 Install the bolts. 3 Connect the side crash sensor electrical connector. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools still in place at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. Install the B-pillar trim panel. 6. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6422 8. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 10. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6423 11. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 12. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6424 15. Connect the passenger air bag module electrical connector. 16. Close the glove box. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the driver air bag module electrical connector. 19. Install the steering wheel access cover. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6425 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Check the restraint system for correct operation. Passenger Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6426 NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Open the glove box past its stops. 3. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6427 4. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. 5. Remove the steering wheel access cover. 6. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6428 8. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 9. Attach the restraint system diagnostic toot to the driver side air bag module floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6429 12. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 14. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 18. Disconnect the battery ground cable and wait at least one minute. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6430 19. Remove the B-pillar trim panel. 20. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6431 ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side crash sensor. 1 Position the side crash sensor to the B-pillar. 2 Install the bolts. 3 Connect the side crash sensor electrical connector. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools still in place at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. Install the B-pillar trim panel. 6. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6432 8. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6433 the bracket under the seat. 12. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6434 15. Connect the driver air bag module electrical connector. 16. Install the steering wheel access cover. 17. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the passenger air bag module electrical connector. 19. Close the glove box. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6435 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Check the restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6436 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts according to this procedure. Weld nuts must be installed according to Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts according to Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6437 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Page 6438 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash ^ monitors the air bag Supplemental Restraint System (SRS) for faults ^ illuminates the air bag indicator if a fault is detected ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs) ^ signals the instrument cluster to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Side Air Bag Module, Right View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Side Air Bag Module, Right > Page 6446 View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Side Air Bag Module, Right Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Side Air Bag Module, Right > Page 6449 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information Side Air Bag: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ INSPECT THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 6452 Side Air Bag: Vehicle Damage Warnings CAUTION: ^ Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. ^ When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. ^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. ^ Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6453 Side Air Bag: Description and Operation Air Bag Module - Driver Side NOTE: ^ References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the Supplemental Restraint System (SRS). ^ When installing a new side air bag module after deployment, refer to Seats. The driver side air bag module: ^ will deploy upon receiving a signal from the Restraints Control Module (RCM) initiated by the driver side crash sensor. ^ is installed as an assembly. ^ is mounted in the driver seat back. Air Bag Module - Passenger Side NOTE: ^ References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the supplemental restraint system (SRS). ^ When installing a new side air bag module after deployment, refer to Seats. The passenger side air bag module: ^ will deploy upon receiving a signal from the restraints control module (RCM) initiated by the passenger side crash sensor. ^ is installed as an assembly. ^ is mounted in the passenger seat back. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6454 Side Air Bag: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6455 ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ If a side air bag deployment took place the seatback pad, trim cover, and side air bag module must be replaced. The seatback frame should be replaced if necessary. ^ When replacing the side air bag after deployment, refer to Seats concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the affected seat from the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES, AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 3. Pry out and remove the seat cushion adjuster handle center plug. NOTE: ^ Use care not to damage the center hole plug. ^ The driver side air bag module removal is shown, the passenger side air bag module removal is similar. 4. Remove the seat cushion adjuster handle. 1 Release the retaining tabs. 2 Pull and remove the seat cushion adjuster handle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6456 5. Remove the outboard seat cushion side shield. 1 Remove the seat backrest lever cover. 2 Remove the screw. 3 Pull out to release the retaining clips and remove the seat cushion side shield. ^ If equipped, disconnect the power seat switch electrical connector. 6. Remove the inboard seat cushion side shield. ^ Pull out to release the retaining clips. 7. Release the pin-type retainers and separate the side air bag electrical connector and wire harness from the seat. NOTE: Note the wire harness routing for installation. 8. Remove the seat backrest pivot nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6457 9. Remove the seat backrest. 1 Remove the seat backrest bolts. 2 Slide the seat backrest pivot stud out of the seat cushion frame and remove the seat backrest. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. 10. Turn the manual lumbar handle clockwise until it stops, releasing all tension on the manual lumbar support cable. 11. Pull and remove the manual lumbar support adjustment handle. 12. Separate the seat backrest trim cover J-retainers. 13. Remove the seat backrest trim cover. 1 Placing a hand between the seat backrest trim cover and pad, carefully separate the hook and loop strips. 2 Roll up the seat back trim cover, in an inside out fashion, and remove the seat backrest trim cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6458 WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 14. Remove the seat backrest pad from the frame. 15. Separate the side air bag module wiring harness pin-type retainers from the seat back frame. 16. Remove the side air bag module. 1 Remove the nuts. 2 Remove the side air bag module. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6459 GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ When replacing the side air bag after deployment, refer to Seats concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side air bag module onto the seat backrest frame mounting bracket. 1 Position the side air bag module to the seat backrest frame mounting bracket. 2 Install the nuts. NOTE: The driver side air bag module installation is shown, the passenger side air bag module installation is similar. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6460 AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. 2. Route the side air bag module wire harness. Install the pin-type retainers to the seat backrest frame. 3. Position the seat backrest pad onto the seat backrest frame. WARNING: INSPECT THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. 4. Install the seat backrest trim cover. 1 Position and roll the seat backrest trim cover down over the seat backrest frame and pad. 2 Attach the hook and loop strips. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6461 5. Attach the seat back trim cover J-retainers. 6. Install the manual lumbar control knob. 7. Install the seat backrest bolts. 1 Align the seat backrest to the seat bottom. 2 Install the seat backrest bolts. CAUTION: When positioning the seat or installing the seat bottom to the seat back, be careful not to damage the seat back pivot or the recliner mechanism. This can cause damage to the seat components. 8. Install the pivot nut. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6462 9. Route the side air bag module wire harness as noted in removal. Install the wire harness and electrical connector pin-type retainers. 10. Install the outboard seat cushion side shield. 1 Align the retaining clips and push inward, seating the retaining clips. ^ If equipped, connect the power seat switch electrical connector. 2 Install the screw. 3 Install the seat backrest lever cover. 11. Install the seat cushion adjuster handle. 12. Install the seat cushion adjuster handle center plug. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6463 13. Align the retaining clips and push inward, installing the inboard seat cushion side shield. 14. Install the affected seat into the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, NOTES AND INSTRUCTIONS IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. 15. Connect the battery ground cable. 16. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 17. Check the active restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 6464 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations View 151-25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6469 Air Bag Control Module: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 6472 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 6473 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash ^ monitors the air bag Supplemental Restraint System (SRS) for faults ^ illuminates the air bag indicator if a fault is detected ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs) ^ signals the instrument cluster to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 6474 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6477 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6478 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the instrument panel, disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6479 8. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 10. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6480 12. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 13. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 14. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6481 18. Disconnect the battery ground cable and wait at least one minute. 19. Position the carpet back at the right-hand side of the center tunnel area under the instrument panel. 20. Remove the right-hand side restraint control module (RCM) retaining bolts. 21. Remove the lower LH center instrument panel finish panel. 22. Position the carpet back at the left-hand side of the center tunnel area under the instrument panel. 23. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking dips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6482 INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6483 2. Tighten the right-hand side RCM bolts. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Reposition the carpet back at the right-hand side of the center tunnel area under the instrument panel. 4. Connect the RCM. 1 Tighten the bolt. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 5. Reposition the carpet back at the left-hand side of the center tunnel area under the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6484 6. Install the lower LH center instrument panel finish panel. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6485 12. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6486 onto the bracket under the seat. 16. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 17. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6487 19. Connect the passenger air bag module electrical connector. 20. Close the glove box. 21. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Connect the driver air bag module electrical connector. 23. Install the steering wheel access cover. 24. Connect the battery ground cable. 25. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6488 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6489 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6490 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the instrument panel, disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6491 8. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 9. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 12. Connect the battery ground cable. 13. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6492 14. Disconnect the battery ground cable and wait at least one minute. 15. Position the carpet back at the right-hand side of the center tunnel area under the instrument panel. 16. Remove the right-hand side restraint control module (RCM) retaining bolts. 17. Remove the lower LH center instrument panel finish panel. 18. Position the carpet back at the left-hand side of the center tunnel area under the instrument panel. 19. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking dips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6493 INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) OPERATION. IF A VEHICLE EQUIPPED WITH AN SRS SYSTEM HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. WARNING: ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6494 2. Tighten the right-hand side RCM bolts. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Reposition the carpet back at the right-hand side of the center tunnel area under the instrument panel. 4. Connect the RCM. 1 Tighten the bolt. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 5. Reposition the carpet back at the left-hand side of the center tunnel area under the instrument panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6495 6. Install the lower LH center instrument panel finish panel. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6496 12. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6497 15. Connect the passenger air bag module electrical connector. 16. Close the glove box. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the driver air bag module electrical connector. 19. Install the steering wheel access cover. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6498 Air Bag Control Module: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts according to this procedure. Weld nuts must be installed according to Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restr.Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts according to Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 6499 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 6500 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6507 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6508 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6509 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6510 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6511 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6512 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions Child Seat Tether Attachment: Service Precautions WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ IT IS IMPORTANT THAT THE BOLT/ANCHOR BE SECURELY TIGHTENED TO SPECIFICATION. OTHERWISE, THE CHILD'S SAFETY SEAT MAY NOT BE PROPERLY SECURED, AND THE CHILD CAN BE INJURED IN CASE OF A SUDDEN STOP OR ACCIDENT. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 6517 Child Seat Tether Attachment: Description and Operation Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Child safety seat tether anchors are manufactured into the vehicle. See the owners manual for locations. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 6518 Child Seat Tether Attachment: Service and Repair REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. At the roof, near the rear liftgate door, remove the child safety seat tether anchor cover. 2. Remove the child safety seat tether anchor. 1 Remove the bolt. 2 Remove the child safety seat tether anchor. INSTALLATION 1. To install, reverse the removal procedure. WARNING: IT IS IMPORTANT THAT THE BOLT/ANCHOR BE SECURELY TIGHTENED TO SPECIFICATION. OTHERWISE, THE CHILD'S SAFETY SEAT MAY NOT BE PROPERLY SECURED, AND THE CHILD CAN BE INJURED IN CASE OF A SUDDEN STOP OR ACCIDENT. NOTE: ^ Rework the sheet metal to its original condition and structural integrity. ^ Make sure to tighten the bolts to specification. 2. Check the active restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt: Customer Interest SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05-3-10 > Feb > 05 > Restraints - Seat Belt Stop Button Service Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 05-3-10 > Feb > 05 > Restraints - Seat Belt Stop Button Service Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Customer Safety Information Seat Belt: Customer Safety Information WARNING: REAR-FACING INFANT SEATS SHOULD NEVER BE PLACED IN THE FRONT SEATS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Customer Safety Information > Page 6543 Seat Belt: Technician Safety Information WARNING: ^ THE DRIVER AND PASSENGER MUST BE PREPARED TO BRACE THEMSELVES IF THE RETRACTOR DOES NOT LOCK. ^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ THE SAFETY BELT BUCKLE PRETENSIONER AND SAFETY BELT RETRACTOR PRETENSIONER ARE PYROTECHNIC DEVICES. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER. ^ CARRY A LIVE SAFETY BELT RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER SO AS TO KEEP FINGERS AND CLOTHING AWAY FROM MOVEABLE PARTS. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG COULD CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Page 6544 Seat Belt: Description and Operation Safety Belt, Lap/Shoulder - Dual Locking Mode WARNING: REAR-FACING INFANT SEATS SHOULD NEVER BE PLACED IN THE FRONT SEATS. The dual locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety belt for the front outboard passenger and both rear outboard seating positions, operates in two ways. The driver single locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety belt works only in the vehicle sensitive mode. 1. In the vehicle-sensitive (emergency locking) mode, the shoulder belt retractor allows the occupant freedom of movement, locking tight only on hard braking, hard cornering or impacts of approximately 8 km/h (5 mph) or more. The front and rear outboard seat belt retractors can also be made to lock by pulling/jerking on the belt. 2. In the automatic locking mode, the shoulder belt retractor automatically locks and remains locked when the combination lap/shoulder safety belt is buckled and does not allow the occupant freedom of movement. This mode provides tight lap/shoulder belt fit on the occupant and on a child safety seat. 3. When the combination lap/shoulder belt is unbuckled and allowed to retract completely, the retractor switches to the vehicle-sensitive (emergency) locking mode. The automatic locking mode must be used when installing a child safety seat in the front outboard passenger and both rear outboard passenger seating positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation Seat Belt: Service and Repair Removal and Installation Rear Safety Belt Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side shown, passenger side is similar. Vehicles with rear power point 1. Disconnect the battery ground cable. Both rear safety belt retractors 2. Remove the rear door scuff plate. 1 Open the cover. 2 Remove the two pin-type retainers (one shown). 3 Remove the rear door scuff plate Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6547 3. Separate the weather-stripping from the C-pillar. 4. Pivot the seat cushion forward. NOTE: LH side shown, RH side similar. 5. Remove the safety belt anchor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt anchor. 6. From behind the rear safety belt guide cover, release the retaining tabs, slide the cover up and remove it. NOTE: The rear safety belt guide has been removed for clarity. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6548 7. Remove the rear safety belt guide. 1 Using the special tool, remove the bolt. 2 Remove the safety belt guide. ^ If necessary, remove the spacer from the rear safety belt guide. 8. Lower the second row seat backrest. 9. Separate the rear hatch weather-stripping along the scuff plate and rear quarter trim panel on the side of the safety belt retractor being serviced. 10. Remove the rear hatch scuff plate. ^ Pull up to release the relaining clips. Vehicles with a cargo cover Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6549 11. Remove the cargo cover. 12. Remove the cargo cover hold-down. RH side only 13. Pull out to release the retaining clips and remove the rear quarter trim panel. LH side only 14. Pull out to release the retaining clips and separate the rear quarter trim panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6550 15. Disconnect the power point connector, if equipped and remove the rear quarter trim panel. Both rear safety belt retractors 16. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION Both rear safety belt retractors 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the C-pillar. 2 Using the special tool, install the bolt. LH side only Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6551 2. Position the rear quarter trim panel and connect the power point electrical connector. Both retractors 3. Install the quarter trim panel. 1 Position the quarter trim panel and feed the safety belt webbing through the opening. 2 Align the quarter trim panel and push in, fastening the retainers. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Vehicles with a cargo cover 4. Install the cargo cover hold-down. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6552 5. Install the cargo cover. Both rear safety belt retractors 6. Install the rear hatch scuff plate. 7. Install the rear hatch weather-stripping. 8. Make sure the spacer is installed onto the rear safety belt guide bolt. 9. Install the rear safety belt guide. 1 Position the safety belt guide. 2 Using the special tool, install the bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6553 NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Install the rear safety belt guide cover. NOTE: If the safety belt guide cover is damaged or if it does not remain in position, install a new cover. 11. Raise the second row seat backrest. 12. Install the safety belt anchor. 1 Position the safety belt anchor. 2 Using the special tool, install the bolt. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6554 13. Install the C-pillar weatherstripping. 14. Install the rear door scuff plate. 1 Position the rear door scuff plate. 2 Install the two pin-type retainers (one shown). 3 Close the cover. 15. Position the seat cushion down. Vehicles with a rear power point 16. Connect the battery ground cable. All vehicles 17. Check the active restraint system for correct operation. 1 Make sure that after the rear safety belt retractor is installed, the retractor is not in the Automatic Locking Retractor (ALR) mode. 2 Carry out the Emergency Locking Retractor (ELR) Mode Functional Test to make sure that the new retractor operates correctly. See: Testing and Inspection/Component Tests and General Diagnostics Front Safety Belt Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6555 PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: The driver side is shown, the passenger side is similar. 1. Remove the B-pillar trim panel. 2. Remove the safety belt anchor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt anchor. 3. Separate the front safety belt retractor from the B-pillar. 1 Remove the bolt. 2 Using the special tool, remove the bolt. 3 Separate the front safety belt retractor from the B-pillar. 4. Remove the front safety belt retractor. 1 Disconnect the front safety belt retractor. 2 Remove the front safety belt retractor. INSTALLATION 1. To install, reverse the removal procedure. ^ Make sure that after the front passenger safety belt retractor is installed, the retractor is not in the Automatic Locking Retractor (ALR) mode. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten bolts to specification. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6556 2. Check the active restraint system for correct operation. ^ Carry out the Emergency Locking Retractor (ELR) Mode Functional Test to make sure that the new retractor operates correctly. See: Testing and Inspection/Component Tests and General Diagnostics Safety Belt - Center, Rear REMOVAL AND INSTALLATION WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the safety belt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6557 Seat Belt: Service and Repair General Procedures Deployed 1. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. WARNING: THE SAFETY BELT PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT BUCKLE PRETENSIONER OR SAFETY BELT RETRACTOR PRETENSIONER. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. Inoperative WARNING: ^ THE SAFETY BELT BUCKLE PRETENSIONER AND SAFETY BELT RETRACTOR PRETENSIONER ARE PYROTECHNIC DEVICES. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT BUCKLE PRETENSIONER OR SAFETY BELT RETRACTOR PRETENSIONER. ^ THE SAFETY BELT BUCKLE PRETENSIONER AND SAFETY BELT RETRACTOR PRETENSIONER ARE PYROTECHNIC DEVICES. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ^ CARRY A LIVE SAFETY BELT RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER SO AS TO KEEP FINGERS AND CLOTHING AWAY FROM MOVEABLE PARTS. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and safety belt retractor pretensioners must be treated the same as any inoperative live safety belt buckle pretensioner or safety belt retractor pretensioner being returned. 1. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from the vehicle. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner to Ford Motor Company. Scrapped Vehicle Remote Deployment WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG COULD CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. 1. Remove the safety belt pretensioner from the vehicle. 2. Cut and strip the wires near the electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 6558 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to stripped ends of the pretensioner wires. 4. Place the pretensioner on a flat surface in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the safety belt pretensioner. 6. Deploy the safety belt pretensioner by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching the deployed safety belt pretensioner. 8. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 6559 Seat Belt: Tools and Equipment Torx Bit, Safety Belt Bolt Seat Belt Bolt Bit Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions > Technician Safety Information Seat Belt Buckle: Technician Safety Information WARNING: ^ THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON A PYROTECHNIC DEVICE. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions > Technician Safety Information > Page 6564 Seat Belt Buckle: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service Precautions > Page 6565 Seat Belt Buckle: Description and Operation The driver and front outboard passenger safety belt buckle and pretensioner are secured to the front seat cushion frame assembly. This allows the front safety belt buckle end to move with the front seat. The belt and buckle assembly pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system. The belt and buckle assembly pretensioner uses the same crash sensor system as the air bag Supplemental Restraint System (SRS). When the belt and buckle assembly pretensioner deploys, the buckle moves downward, pulling excess webbing from the lap and shoulder safety belts. If the safety belt buckle and pretensioner assembly is deployed, a new assembly must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner Seat Belt Buckle: Service and Repair Safety Belt Buckle and Pretensioner Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ^ THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON A PYROTECHNIC DEVICE. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6568 SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the affected seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: Make sure to follow all steps and instructions in the removal procedure of the affected seat. 3. Remove the inboard seat cushion side shield. ^ Pull out to release the retaining clips. NOTE: The driver seat safety belt buckle and pretensioner is shown, the passenger side is similar. 4. Release the pin-type retainers and separate the safety belt buckle and pretensioner electrical connector and wire harness from the seat. NOTE: Note the wire harness routing for installation. 5. Remove the safety belt buckle and pretensioner. 1 Using the special tool, remove the bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6569 2 Remove the safety belt buckle and pretensioner. NOTE: Do not handle the safety belt buckle and pretensioner in the area of the safety belt buckle and pretensioner cable or retaining nut. Accidental pretensioner deployment could occur and result in personal injury. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped;) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ The driver seat safety belt buckle and pretensioner is shown, the passenger side is similar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6570 1. Install the safety belt buckle and pretensioner. 1 Position the safety belt buckle and pretensioner to the seat cushion frame. 2 Align and install the anti-rotation tab of the safety belt buckle and pretensioner to the slot in the seat cushion frame. 3 Using the special tool, install the bolt. 2. Route the safety belt buckle and pretensioner wire harness as noted in removal. Install the wire harness and electrical connector pin-type retainers. 3. Align the retaining clips and push in, installing the inboard seat cushion side shield. 4. Install the affected seat into the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: Make sure to follow all steps and instructions in the installation procedure of the affected seat. 5. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Check the active restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6571 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Center and Passenger Side, Rear Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Pivot the seat bottom forward. 2. Pivot the seat backrest back. 3. Remove the safety belt buckle assembly. 1 Position the carpet out of the way. 2 Using the special tool, remove the bolt. 3 Remove the safety belt buckle assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ Make sure the safety belt webbing is not twisted prior to repositioning the seat. ^ Make sure that the safety belt buckles are accessible after repositioning the seat. ^ Make sure to tighten the bolt to specification. 2. Check the active restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6572 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Driver Side, Rear Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Pivot the seat bottom forward. 2. Pivot the seat backrest back. 3. Remove the safety belt and buckle assembly. 1 Position the carpet out of the way. 2 Using the special tool, remove the bolt. 3 Feed the safety belt and buckle through the carpet and remove the assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ Make sure the safety belt webbing is not twisted after repositioning the seat. ^ Make sure that the safety belt and buckle are accessible after repositioning the seat. ^ Make sure to tighten the bolt to specification. 2. Check the restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Page 6573 Seat Belt Bolt Bit Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt Buckle Switch: Customer Interest SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt Buckle Switch: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 6587 View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 6588 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation A safety belt that is too short even when fully extended can be lengthened. The safety belt extension is available. This assembly will add approximately 20 cm (8 inches) to the length of the safety belt. Use the safety belt extension only if the safety belt is too short when fully extended. Do not use the safety belt extension to change the fit of the shoulder belt across the torso. Safety belt extensions are available at no cost from any authorized Ford or Lincoln-Mercury dealer. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service Precautions Seat Belt Height Adjuster: Service Precautions WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: The driver side is shown, the passenger side is similar. 1. Remove the B-pillar trim panel. 2. Lower the height adjuster. 3. Remove the upper height adjuster bolt. 4. Raise the height adjuster. 5. Remove the height adjuster. 1 Remove the bolt. 2 Remove the height adjuster. INSTALLATION 1. To install, reverse the removal procedure. ^ Make sure that the front safety belt retractor is not in the Automatic Locking Retractor (ALR) mode. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten bolts to specification. 2. Check the active restraint system for correct operation. ^ Carry out the Emergency Locking Retractor (ELR) Mode Functional Test to make sure that the new retractor operates correctly. See: Testing and Inspection/Component Tests and General Diagnostics Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 6597 Seat Belt Height Adjuster: Service and Repair General Procedures D-Ring Installation Kit SPECIAL TOOL(S) 1. Remove the trim panels. 2. Use the half-inch drill provided in D-Ring Installation Kit 100-F012 (134-00018) or equivalent to drill out the damaged threads in the upper B-pillar structure. 3. Apply a suitable lubricant to the M14x1.5 tap provided in D-Ring Installation Kit 100-F012 (134-00018) and tap new threads. NOTE: After each rotation, back tap off slightly to remove new cuttings and be sure to clean out any chips before proceeding. 4. Use a threaded insert provided in D-Ring Installation Kit 100-F012 (134-00018) or equivalent and screw it into the retapped hole until it is slightly below the surface of the hole. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 6598 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit 100-F012 (134-00018) several times to drive down the insert keys. NOTE: If the two hex-head bolts on the front seat shoulder strap adjuster are not stripped, refer to Safety Belt Shoulder Height Adjuster to install the height adjuster to the body. If the front seat shoulder strap adjuster bolts are stripped, replace the adjuster. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6599 D-Ring Installation Kit Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning System The safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten their safety belts. The conditions of operation for the safety belt warning indicator and chime are as follows: ^ If the driver's safety belt is not buckled before the ignition switch is turned to RUN, the safety belt warning indicator illuminates for 1-2 minutes and the warning chime sounds for 4-8 seconds. ^ If the driver's safety belt is buckled while the warning indicator is illuminated and the reminder chime is sounding, the safety belt warning indicator and reminder chime turn off. ^ If the driver's safety belt is buckled before the ignition switch is turned to RUN, the safety belt warning indicator and reminder chime remain off. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning System The safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten their safety belts. The conditions of operation for the safety belt warning indicator and chime are as follows: ^ If the driver's safety belt is not buckled before the ignition switch is turned to RUN, the safety belt warning indicator illuminates for 1-2 minutes and the warning chime sounds for 4-8 seconds. ^ If the driver's safety belt is buckled while the warning indicator is illuminated and the reminder chime is sounding, the safety belt warning indicator and reminder chime turn off. ^ If the driver's safety belt is buckled before the ignition switch is turned to RUN, the safety belt warning indicator and reminder chime remain off. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 6614 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 6620 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions > Customer Safety Information Seat Belt Retractor: Customer Safety Information WARNING: REAR-FACING INFANT SEATS SHOULD NEVER BE PLACED IN THE FRONT SEATS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions > Customer Safety Information > Page 6623 Seat Belt Retractor: Technician Safety Information WARNING: ^ THE DRIVER AND PASSENGER MUST BE PREPARED TO BRACE THEMSELVES IF THE RETRACTOR DOES NOT LOCK. ^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service Precautions > Page 6624 Seat Belt Retractor: Description and Operation WARNING: REAR-FACING INFANT SEATS SHOULD NEVER BE PLACED IN THE FRONT SEATS. The dual locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety belt for the front outboard passenger and both rear outboard seating positions, operates in two ways. The driver single locking mode retractor on the shoulder belt portion of the combination lap/shoulder safety belt works only in the vehicle sensitive mode. 1. In the vehicle-sensitive (emergency locking) mode, the shoulder belt retractor allows the occupant freedom of movement, locking tight only on hard braking, hard cornering or impacts of approximately 8 km/h (5 mph) or more. The front and rear outboard seat belt retractors can also be made to lock by pulling/jerking on the belt. 2. In the automatic locking mode, the shoulder belt retractor automatically locks and remains locked when the combination lap/shoulder safety belt is buckled and does not allow the occupant freedom of movement. This mode provides tight lap/shoulder belt fit on the occupant and on a child safety seat. 3. When the combination lap/shoulder belt is unbuckled and allowed to retract completely, the retractor switches to the vehicle-sensitive (emergency) locking mode. The automatic locking mode must be used when installing a child safety seat in the front outboard passenger and both rear outboard passenger seating positions. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor Seat Belt Retractor: Service and Repair Front Safety Belt Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: The driver side is shown, the passenger side is similar. 1. Remove the B-pillar trim panel. 2. Remove the safety belt anchor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt anchor. 3. Separate the front safety belt retractor from the B-pillar. 1 Remove the bolt. 2 Using the special tool, remove the bolt. 3 Separate the front safety belt retractor from the B-pillar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6627 4. Remove the front safety belt retractor. 1 Disconnect the front safety belt retractor. 2 Remove the front safety belt retractor. INSTALLATION 1. To install, reverse the removal procedure. ^ Make sure that after the front passenger safety belt retractor is installed, the retractor is not in the Automatic Locking Retractor (ALR) mode. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten bolts to specification. 2. Check the active restraint system for correct operation. ^ Carry out the Emergency Locking Retractor (ELR) Mode Functional Test to make sure that the new retractor operates correctly. See: Testing and Inspection/Component Tests and General Diagnostics Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6628 Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side shown, passenger side is similar. Vehicles with rear power point 1. Disconnect the battery ground cable. Both rear safety belt retractors 2. Remove the rear door scuff plate. 1 Open the cover. 2 Remove the two pin-type retainers (one shown). 3 Remove the rear door scuff plate 3. Separate the weather-stripping from the C-pillar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6629 4. Pivot the seat cushion forward. NOTE: LH side shown, RH side similar. 5. Remove the safety belt anchor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt anchor. 6. From behind the rear safety belt guide cover, release the retaining tabs, slide the cover up and remove it. NOTE: The rear safety belt guide has been removed for clarity. 7. Remove the rear safety belt guide. 1 Using the special tool, remove the bolt. 2 Remove the safety belt guide. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6630 ^ If necessary, remove the spacer from the rear safety belt guide. 8. Lower the second row seat backrest. 9. Separate the rear hatch weather-stripping along the scuff plate and rear quarter trim panel on the side of the safety belt retractor being serviced. 10. Remove the rear hatch scuff plate. ^ Pull up to release the relaining clips. Vehicles with a cargo cover 11. Remove the cargo cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6631 12. Remove the cargo cover hold-down. RH side only 13. Pull out to release the retaining clips and remove the rear quarter trim panel. LH side only 14. Pull out to release the retaining clips and separate the rear quarter trim panel. 15. Disconnect the power point connector, if equipped and remove the rear quarter trim panel. Both rear safety belt retractors Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6632 16. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION Both rear safety belt retractors 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the C-pillar. 2 Using the special tool, install the bolt. LH side only 2. Position the rear quarter trim panel and connect the power point electrical connector. Both retractors Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6633 3. Install the quarter trim panel. 1 Position the quarter trim panel and feed the safety belt webbing through the opening. 2 Align the quarter trim panel and push in, fastening the retainers. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Vehicles with a cargo cover 4. Install the cargo cover hold-down. 5. Install the cargo cover. Both rear safety belt retractors Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6634 6. Install the rear hatch scuff plate. 7. Install the rear hatch weather-stripping. 8. Make sure the spacer is installed onto the rear safety belt guide bolt. 9. Install the rear safety belt guide. 1 Position the safety belt guide. 2 Using the special tool, install the bolt. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 10. Install the rear safety belt guide cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6635 NOTE: If the safety belt guide cover is damaged or if it does not remain in position, install a new cover. 11. Raise the second row seat backrest. 12. Install the safety belt anchor. 1 Position the safety belt anchor. 2 Using the special tool, install the bolt. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 13. Install the C-pillar weatherstripping. 14. Install the rear door scuff plate. 1 Position the rear door scuff plate. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 6636 2 Install the two pin-type retainers (one shown). 3 Close the cover. 15. Position the seat cushion down. Vehicles with a rear power point 16. Connect the battery ground cable. All vehicles 17. Check the active restraint system for correct operation. 1 Make sure that after the rear safety belt retractor is installed, the retractor is not in the Automatic Locking Retractor (ALR) mode. 2 Carry out the Emergency Locking Retractor (ELR) Mode Functional Test to make sure that the new retractor operates correctly. See: Testing and Inspection/Component Tests and General Diagnostics Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Page 6637 Seat Belt Retractor: Tools and Equipment Torx Bit, Safety Belt Bolt Seat Belt Bolt Bit Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat > Page 6642 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service Precautions > Technician Safety Information Seat Belt Tensioner: Technician Safety Information WARNING: ^ THE SAFETY BELT BUCKLE PRETENSIONER AND SAFETY BELT RETRACTOR PRETENSIONER ARE PYROTECHNIC DEVICES. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ CARRY A LIVE SAFETY BELT RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER SO AS TO KEEP FINGERS AND CLOTHING AWAY FROM MOVEABLE PARTS. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG COULD CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service Precautions > Technician Safety Information > Page 6645 Seat Belt Tensioner: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Occupant Restraints - Active Seat Belt Tensioner: Description and Operation Occupant Restraints - Active The driver and front outboard passenger safety belt buckle and pretensioner are secured to the front seat cushion frame assembly. This allows the front safety belt buckle end to move with the front seat. The belt and buckle assembly pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system. The belt and buckle assembly pretensioner uses the same crash sensor system as the air bag Supplemental Restraint System (SRS). When the belt and buckle assembly pretensioner deploys, the buckle moves downward, pulling excess webbing from the lap and shoulder safety belts. If the safety belt buckle and pretensioner assembly is deployed, a new assembly must be installed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Occupant Restraints - Active > Page 6648 Seat Belt Tensioner: Description and Operation Occupant Restraints - Passive - Supplemental Air Bag System As part of the Supplemental Restraint System (SRS), the safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated by the restraints control module (RCM) when the module detects a crash event force exceeding a programmed unit. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active Seat Belt Tensioner: Service and Repair Occupant Restraints - Active Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ^ THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG-EQUIPPED VEHICLE AND WHEN HANDLING A BELT AND BUCKLE ASSEMBLY PRETENSIONER. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ THE BELT AND BUCKLE ASSEMBLY PRETENSIONER IS A PYROTECHNIC DEVICE. NEVER PROBE THE CONNECTORS ON A PYROTECHNIC DEVICE. DOING SO COULD RESULT IN BELT AND BUCKLE ASSEMBLY PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 6651 SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the affected seat from the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: Make sure to follow all steps and instructions in the removal procedure of the affected seat. 3. Remove the inboard seat cushion side shield. ^ Pull out to release the retaining clips. NOTE: The driver seat safety belt buckle and pretensioner is shown, the passenger side is similar. 4. Release the pin-type retainers and separate the safety belt buckle and pretensioner electrical connector and wire harness from the seat. NOTE: Note the wire harness routing for installation. 5. Remove the safety belt buckle and pretensioner. 1 Using the special tool, remove the bolt. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 6652 2 Remove the safety belt buckle and pretensioner. NOTE: Do not handle the safety belt buckle and pretensioner in the area of the safety belt buckle and pretensioner cable or retaining nut. Accidental pretensioner deployment could occur and result in personal injury. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped;) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat Systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ The driver seat safety belt buckle and pretensioner is shown, the passenger side is similar. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 6653 1. Install the safety belt buckle and pretensioner. 1 Position the safety belt buckle and pretensioner to the seat cushion frame. 2 Align and install the anti-rotation tab of the safety belt buckle and pretensioner to the slot in the seat cushion frame. 3 Using the special tool, install the bolt. 2. Route the safety belt buckle and pretensioner wire harness as noted in removal. Install the wire harness and electrical connector pin-type retainers. 3. Align the retaining clips and push in, installing the inboard seat cushion side shield. 4. Install the affected seat into the vehicle. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: Make sure to follow all steps and instructions in the installation procedure of the affected seat. 5. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Check the active restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 6654 Seat Belt Tensioner: Service and Repair Occupant Restraints - Passive - Supplemental Air Bag System Deployed 1. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. WARNING: THE SAFETY BELT PRETENSIONER IS A PYROTECHNIC DEVICE. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT BUCKLE PRETENSIONER OR SAFETY BELT RETRACTOR PRETENSIONER. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. Inoperative WARNING: ^ THE SAFETY BELT BUCKLE PRETENSIONER AND SAFETY BELT RETRACTOR PRETENSIONER ARE PYROTECHNIC DEVICES. ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG EQUIPPED VEHICLE AND WHEN HANDLING A SAFETY BELT BUCKLE PRETENSIONER OR SAFETY BELT RETRACTOR PRETENSIONER. ^ THE SAFETY BELT BUCKLE PRETENSIONER AND SAFETY BELT RETRACTOR PRETENSIONER ARE PYROTECHNIC DEVICES. NEVER PROBE A PRETENSIONER ELECTRICAL CONNECTOR. DOING SO COULD RESULT IN PRETENSIONER OR AIR BAG DEPLOYMENT AND COULD RESULT IN PERSONAL INJURY. ^ CARRY A LIVE SAFETY BELT RETRACTOR PRETENSIONER OR SAFETY BELT BUCKLE PRETENSIONER SO AS TO KEEP FINGERS AND CLOTHING AWAY FROM MOVEABLE PARTS. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and safety belt retractor pretensioners must be treated the same as any inoperative live safety belt buckle pretensioner or safety belt retractor pretensioner being returned. 1. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from the vehicle. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner to Ford Motor Company. Scrapped Vehicle Remote Deployment WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG COULD CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. 1. Remove the safety belt pretensioner from the vehicle. 2. Cut and strip the wires near the electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Occupant Restraints - Active > Page 6655 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to stripped ends of the pretensioner wires. 4. Place the pretensioner on a flat surface in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the safety belt pretensioner. 6. Deploy the safety belt pretensioner by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching the deployed safety belt pretensioner. 8. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Page 6656 Safety Belt Bolt Bit Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Side Air Bag Sensor, Left > Page 6662 View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right > Page 6665 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 6668 Impact Sensor: Technician Safety Information WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 6669 Impact Sensor: Description and Operation WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. For this vehicle, the SRS employs three crash sensors. One of the sensors is integral to the RCM and is not serviceable separately. In addition, there are two side crash sensors located in the LH and RH B-pillars. The RCM is mounted on the center tunnel under the instrument panel. Mounting orientation is critical for correct operation of all crash sensors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6672 be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR, TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the steering wheel access cover. 3. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6673 4. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Open the glove box past its stops. 6. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6674 8. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 10. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6675 12. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the driver side air bag module floor electrical connector. 14. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 18. Disconnect the battery ground cable and wait at least one minute. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6676 19. Remove the B-pillar trim panel. 20. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6677 seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side crash sensor. 1 Position the side crash sensor to the B-pillar. 2 Install the bolts. 3 Connect the side crash sensor electrical connector. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools still in place at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. Install the B-pillar trim panel. 6. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6678 8. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 10. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6679 11. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. 12. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6680 15. Connect the passenger air bag module electrical connector. 16. Close the glove box. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the driver air bag module electrical connector. 19. Install the steering wheel access cover. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6681 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Check the restraint system for correct operation. Passenger Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6682 NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Open the glove box past its stops. 3. Through the glove box opening toward the center of the Instrument Panel (I/P), disconnect the passenger air bag module electrical connector. 1 Push to release the passenger air bag module electrical connector locking clip. 2 Disconnect the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6683 4. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. 5. Remove the steering wheel access cover. 6. Disconnect the driver air bag module electrical connector. 1 Push to release the driver air bag module electrical connector locking clip. 2 Disconnect the driver air bag module electrical connector. 7. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6684 8. Disconnect the driver side air bag module electrical connector. 1 Slide and release the driver side air bag module electrical connector locking clip. 2 Disconnect the driver side air bag module electrical connector. 9. Attach the restraint system diagnostic toot to the driver side air bag module floor electrical connector. 10. Disconnect the driver safety belt buckle pretensioner electrical connector. 1 Remove the driver safety belt buckle pretensioner electrical connector from the under the seat bracket. 2 Push to release the driver safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the driver safety belt buckle pretensioner electrical connector. 11. Attach the restraint system diagnostic tool to the driver safety belt buckle pretensioner floor electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6685 12. Disconnect the passenger side air bag module electrical connector. 1 Slide and release the passenger side air bag module electrical connector locking clip. 2 Disconnect the passenger side air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the passenger side air bag module floor electrical connector. 14. Disconnect the passenger safety belt buckle pretensioner electrical connector. 1 Remove the passenger safety belt buckle pretensioner electrical connector from the bracket under the seat. 2 Push to release the passenger safety belt buckle pretensioner electrical connector locking clip. 3 Disconnect the passenger safety belt buckle pretensioner electrical connector. 15. Attach the restraint system diagnostic tool to the passenger safety belt buckle pretensioner floor electrical connector. 16. Connect the battery ground cable. 17. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 18. Disconnect the battery ground cable and wait at least one minute. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6686 19. Remove the B-pillar trim panel. 20. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the side crash sensor. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag and/or a safety belt pretensioner (if equipped) system is being serviced the airbag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the side airbag and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a side airbag system and/or a safety belt pretensioner (if equipped) system with the seats in the vehicle. Prior to attempting to diagnose/repair the side airbag system and/or a safety belt pretensioner (if equipped) system the seats must be removed from the vehicle and the restraint system diagnostic tools must be installed in the side airbag and the safety belt pretensioner (if equipped) connectors at the floor connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ Diagnostics may be performed on seat systems other than the side airbag or the safety belt pretensioner (if equipped) system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tools are installed under the seats in the side airbag and safety belt pretensioner to floor connectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6687 ^ After diagnosing/repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side crash sensor. 1 Position the side crash sensor to the B-pillar. 2 Install the bolts. 3 Connect the side crash sensor electrical connector. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools still in place at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. Install the B-pillar trim panel. 6. Remove the restraint system diagnostic tool from the passenger safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Connect the passenger safety belt buckle pretensioner electrical connector. Install the passenger safety belt buckle pretensioner electrical connector onto the bracket under the seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6688 8. Remove the restraint system diagnostic tool from the passenger side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Connect the passenger side air bag module electrical connector. Install the passenger side air bag module electrical connector onto the bracket under the seat. 10. Remove the restraint system diagnostic tool from the driver safety belt buckle pretensioner floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Connect the driver safety belt buckle pretensioner electrical connector. Install the driver safety belt buckle pretensioner electrical connector onto Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6689 the bracket under the seat. 12. Remove the restraint system diagnostic tool from the driver side air bag module floor electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Connect the driver side air bag module electrical connector. Install the driver side air bag module electrical connector onto the bracket under the seat. 14. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6690 15. Connect the driver air bag module electrical connector. 16. Install the steering wheel access cover. 17. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Connect the passenger air bag module electrical connector. 19. Close the glove box. 20. Connect the battery ground cable. 21. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6691 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 22. Check the restraint system for correct operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6692 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts according to this procedure. Weld nuts must be installed according to Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts according to Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 6693 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, Restr. Ctrl Module (RCM)/Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 6694 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash ^ monitors the air bag Supplemental Restraint System (SRS) for faults ^ illuminates the air bag indicator if a fault is detected ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs) ^ signals the instrument cluster to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt Buckle Switch: Customer Interest SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 05-17-11 > Sep > 05 > SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set Seat Belt Buckle Switch: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC's B1877/B1881 Set TSB 05-17-11 09/05/05 RESTRAINT SYSTEM - SAFETY BELT BUCKLE AND PRETENSIONER DIAGNOSTIC TROUBLE CODE (DTC) B1877 AND/OR B1881 FORD: 2001-2004 Escape This article supersedes TSB 04-24-4 to update the service procedure. ISSUE Some 2001-2004 Escape vehicles may exhibit an intermittent air bag lamp on and diagnostic trouble code (DTC) B1877 and/or B1881. This may be caused by a variation in the electrical continuity between the pins of the driver and/or passenger side wiring harness and the buckle pretensioner connector. If this condition were to occur, the air bag system remains fully functional. ACTION Install a replacement harness connector kit ON BOTH the driver and passenger safety belt buckle pretensioners, even if the DTC is present for only one side. The kit includes improved connector halves to replace the existing connectors on both the body harness and the safety belt buckle pretensioner. One kit is required per side (2 kits per vehicle). Refer to the instruction sheet included in the kit for complete repair procedure. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051711A 2001-2004 Escape Install 2.0 Hrs. A Replacement Harness Connector On Both The Body Side And Safety Belt Buckle Pretensioner Harness For Both Driver And Passenger Safety Belt Buckle Pretensioners (Do Not Use With 14056D) DEALER CODING CONDITION BASIC PART NO. CODE 7861202 OR 7861203 X2 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 6711 View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 6712 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6718 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6719 Accessory Delay Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6720 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair ANTENNA UPPER CABLE REMOVAL 1. Remove the audio unit. 2. Remove the right lower A-pillar trim. 3. Disconnect the antenna cable connector. 4. Lower the glove box door. 5. Remove the three pin-type retainers holding the lead-in cable. 6. Remove the antenna cable clip fastened to the center instrument panel support. 7. Remove the cable through the glove box opening. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 6726 INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Application and ID Alarm Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 6734 Alarm System Transponder: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER REMOVAL 1. Disconnect the battery ground cable. 2. Pull the tilt wheel lever down in open position, as necessary. 3. Remove the lower instrument panel steering column cover. 1 Remove the lower instrument panel steering column cover. 2 Remove the screws. 3 Remove the upper and lower steering column shrouds. 4. Remove the transceiver assembly. 1 Disconnect the electrical connector. 2 Remove the screw. 3 Remove the transceiver assembly. INSTALLATION 1. NOTE: No key replacement or re-initialization needs to occur with the removal or installation of a new PATS transceiver. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6738 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 6744 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 6745 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair REMOTE TRANSMITTER PROGRAMMING NOTE: - All keyless entry remote transmitters must be programmed at the same time. - All previous transmitter identification codes (TIC's) will be erased when programming mode is entered. - To program (or reprogram) the keyless entry remote transmitters into the generic electronic module (GEM), carry out the following steps. 1. Turn the ignition from OFF to RUN eight times within 10 seconds, ending in RUN. If the GEM has successfully entered program mode, it will lock and unlock all the doors. 2. NOTE: The first TIC must be entered within 7.5 seconds of entering the program mode and additional TICs must be entered within 7.5 seconds of the first TIC. The programming mode is exited whenever the timing constraints are not met. Press any button on a keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait for several seconds and press the button again. 4. Turn the ignition switch to the OFF position, or wait up to five minutes after step 1, to exit program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the GEM will lock and unlock all the doors one last time. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 6756 Parking Assist Control Module: Service and Repair PARKING AID MODULE REMOVAL 1. Remove the right rear quarter trim panel. 2. Remove the parking aid module. 1 Remove the screws. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6765 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6766 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6767 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6768 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6774 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6775 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6776 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6777 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 6780 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 6781 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 6782 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 6783 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR REMOVAL 1. NOTE: The rear bumper removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper removal for access. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams > Page 6787 Parking Assist Switch: Service and Repair PARKING AID SWITCH REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the parking aid switch. 1 Disconnect the electrical connector. 2 Press the tabs. 3 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Description and Operation > Module Controlled Functions General Module: Description and Operation Module Controlled Functions MODULE CONTROLLED FUNCTIONS The multifunction module consists of the generic electronic module (GEM). The GEM controls the following features: - interval rear window wiper - battery saver - illuminated entry - headlamp control - interior lamp control - power door locks - remote keyless entry (RKE) - accessory delay - perimeter anti-theft system - door ajar output control Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Description and Operation > Module Controlled Functions > Page 6796 General Module: Description and Operation Principles of Operation (How Does It Work?) PRINCIPLES OF OPERATION The generic electronic module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a diagnostic trouble code (DTC). The ignition switch position is very important to the GEM function. Erratic or unexpected GEM function can often be traced to problems with these GEM inputs. The GEM controls a variety of systems: - interval rear window wiper - battery saver - illuminated entry - headlamp control - interior lamp control - power door locks - remote keyless entry (RKE) - accessory delay - perimeter anti-theft system - door ajar output control Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview General Module: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical Fuse - Wiring harness - Connector(s) - Circuitry - Generic electronic module (GEM) 3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: - CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). - NO RESP/NOT EQUIP for generic electronic module (GEM), go to Pinpoint Test A. See: Pinpoint Tests - SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate system to continue diagnostics. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6799 General Module: Diagnostic Trouble Code Tests and Associated Procedures DTC Index B1217 - B1318 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6800 DTC Index B1319 - B2494 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6801 DTC Index B2495 - C1962 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6802 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6803 General Module: Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC ELECTRONIC MODULE (GEM) Test A1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6804 Test A2-A3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6805 Test A4-A5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 6806 General Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) REMOVAL 1. NOTE: Prior to removal of the GEM, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the pin-type retainer and the lower shield. 3. Position the RH and LH carpet aside from the center tunnel. 4. Disconnect the GEM electrical connectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 6807 5. Remove the GEM 1 Pull back the insulation and remove the nuts. 2 Remove the GEM. INSTALLATION 1. To install, reverse the removal procedure. - Configure the GEM. Refer to Module Communications Network (Information Bus). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 6808 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Testing and Inspection Audio Control Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Testing and Inspection > Page 6816 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 6822 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 6823 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 6824 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 6825 Speaker: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 6826 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 6827 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 6828 Speaker: Description and Operation SPEAKERS All vehicles are equipped with four radio speakers mounted in the doors. The optional tweeters are mounted in the sail panels and the optional woofer is mounted in the right rear quarter panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6834 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6835 Accessory Delay Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6836 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Application and ID Alarm Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Testing and Inspection Audio Control Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Testing and Inspection > Page 6843 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Specifications Torque Specifications Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Description and Operation > Module Controlled Functions General Module: Description and Operation Module Controlled Functions MODULE CONTROLLED FUNCTIONS The multifunction module consists of the generic electronic module (GEM). The GEM controls the following features: - interval rear window wiper - battery saver - illuminated entry - headlamp control - interior lamp control - power door locks - remote keyless entry (RKE) - accessory delay - perimeter anti-theft system - door ajar output control Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Description and Operation > Module Controlled Functions > Page 6849 General Module: Description and Operation Principles of Operation (How Does It Work?) PRINCIPLES OF OPERATION The generic electronic module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a diagnostic trouble code (DTC). The ignition switch position is very important to the GEM function. Erratic or unexpected GEM function can often be traced to problems with these GEM inputs. The GEM controls a variety of systems: - interval rear window wiper - battery saver - illuminated entry - headlamp control - interior lamp control - power door locks - remote keyless entry (RKE) - accessory delay - perimeter anti-theft system - door ajar output control Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview General Module: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical Fuse - Wiring harness - Connector(s) - Circuitry - Generic electronic module (GEM) 3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 4. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: - CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). - NO RESP/NOT EQUIP for generic electronic module (GEM), go to Pinpoint Test A. See: Pinpoint Tests - SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate system to continue diagnostics. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6852 General Module: Diagnostic Trouble Code Tests and Associated Procedures DTC Index B1217 - B1318 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6853 DTC Index B1319 - B2494 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6854 DTC Index B2495 - C1962 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6855 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6856 General Module: Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC ELECTRONIC MODULE (GEM) Test A1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6857 Test A2-A3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6858 Test A4-A5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 6859 General Module: Service and Repair GENERIC ELECTRONIC MODULE (GEM) REMOVAL 1. NOTE: Prior to removal of the GEM, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the pin-type retainer and the lower shield. 3. Position the RH and LH carpet aside from the center tunnel. 4. Disconnect the GEM electrical connectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 6860 5. Remove the GEM 1 Pull back the insulation and remove the nuts. 2 Remove the GEM. INSTALLATION 1. To install, reverse the removal procedure. - Configure the GEM. Refer to Module Communications Network (Information Bus). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 6861 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 6868 Parking Assist Control Module: Service and Repair PARKING AID MODULE REMOVAL 1. Remove the right rear quarter trim panel. 2. Remove the parking aid module. 1 Remove the screws. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6873 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6882 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6883 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6884 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6885 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6891 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6892 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6893 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 6894 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 6897 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 6898 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 6899 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 6900 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR REMOVAL 1. NOTE: The rear bumper removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper removal for access. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 6904 Parking Assist Switch: Service and Repair PARKING AID SWITCH REMOVAL 1. Remove the instrument panel center finish panel. 2. Remove the parking aid switch. 1 Disconnect the electrical connector. 2 Press the tabs. 3 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 Trailer Connector: Electrical Diagrams Trailer/Camper Adapter PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 Trailer Lamps: Electrical Diagrams Trailer/Camper Adapter PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse: 21 (10A) - 16 (10A) - Connections - Circuitry - Relays - Bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6957 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6958 Trailer Lamps: Pinpoint Tests Tests AB PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE Test AB1 Tests AC PINPOINT TEST AC: THE TRAILER LAMPS ARE INOPERATIVE - BOTH TRAILER TURN SIGNALS/STOPLAMPS/HAZARD LAMPS Test AC1-AC2 Tests AD PINPOINT TEST AD: THE INDIVIDUAL TRAILER LAMPS IS INOPERATIVE - RH TRAILER TURN SIGNALS/STOPLAMPS/HAZARD Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6959 LAMPS Test AD1 Tests AE PINPOINT TEST AE: THE INDIVIDUAL TRAILER LAMPS IS INOPERATIVE-LH TRAILER TURN SIGNALS/STOPLAMPS/HAZARD LAMPS Test AE1 Tests AF PINPOINT TEST AF: THE INDIVIDUAL TRAILER LAMPS IS INOPERATIVE-PARKING LAMPS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6960 Test AF1-AF2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 6961 73III Automotive Meter Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Trailer Connector: Electrical Diagrams Trailer/Camper Adapter PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 Body Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Body Control Module: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Body Control Module: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 59-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 59-2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 59-3 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT BUMPER COVER Removal and Installation 1. Raise and support the vehicle. 2. Remove the six pin-type retainers (three each 3. Remove the foul front bumper cover bolt (two each side). 4. Remove and discard the two front bumper cover-to-front fender pin-type retainers (one each side). 5. If equipped, disconnect the fog lamp electrical connectors. 6. Remove the lower front bumper cover bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 7022 7. Remove the pin-type retainers. 8. Lower the vehicle. 9. Remove the two upper bolts (one each side) and the front bumper cover. 10. To install, reverse the removal procedure. - When installing, be sure to position the front bumper cover into the bumper slides. - Transfer components as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER Removal and Installation 1. Remove the front bumper cover. 2. Remove the front bumper. 1 Remove the four front bumper nuts (two each side). 2 Remove the front bumper. 3. To install. reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR BUMPER COVER Removal and Installation 1. If equipped, disconnect the parking aid system electrical connector. 2. Remove the six rear splash shield bolts (three each side). 3. Remove the two rear bumper cover to rear quarter panel screws (one each side). 4. Remove the four pin-type retainers. 5. Remove the rear bumper cover. 1 Remove the screws. 2 Remove the bolts and the liftgate alignment bumpers. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 7030 3 Remove the rear bumper cover. 6. To install, reverse the removal procedure. - When installing. be sure to position the rear bumper cover into the bumper slides. - Transfer components as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER Removal and Installation 1. Remove the rear bumper cover. 2. Remove the rear bumper. 1 Remove the four rear bumper nuts (two each side). 2 Remove the rear bumper. 3. To install. reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the wiper pivot arms. 1 Remove the nuts. 2 Remove the wiper pivot arm. 2. Remove the driver side cowl grille. 1 Remove the pin-type retainers. 2 Remove the screw caps and screws. 3 Remove the cowl grille. 3. Remove the passenger side cowl grille. 1 Remove the pin-type retainers. 2 Remove the screw caps and screws. 3 Remove the cowl grille. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR FRONT DOOR HANDLE REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Loosen the door latch remote control screw. 4. Remove the exterior door handle cover. 1 Pull the exterior door handle. 2 The front of the cover must be released prior to removing. 5. Remove the exterior door handle by sliding towards the rear of the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 7045 6. Remove the exterior door handle seals. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair INTERIOR DOOR HANDLE REMOVAL 1. Remove the door trim panel. 2. Position the watershield aside. 3. Remove the interior door handle. - Release the clip. 4. Remove the door latch cable. 1 Disconnect the cable conduit. 2 Remove the door latch cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments Front Door Hinge: Adjustments HINGE ADJUSTMENT - FRONT DOOR LH and RH sides NOTE: Make sure the rear door is within specification before making any adjustments to the front door. Refer to the specification chart. See: Specifications 1. Remove the fender. 2. Mark the positions of the front door hinges to use as reference points. 3. Loosen the two front door hinge-to-body bolts just enough to permit movement. 4. Remove the A-pillar lower trim panel. 1 Remove the pin-type retainer. 2 Remove the A-pillar lower trim panel. LH side Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7052 5. Position the central junction box (CJB) aside. 1 Remove the nuts. 2 Position the CJB aside. RH side 6. Position the inertia fuel shutoff (IFS) switch bracket aside. 1 Remove the bolts. 2 Position the bracket aside. LH and RH sides 7. Loosen the lower door hinge bolt just enough to permit movement. 8. Adjust the front door to specification. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7053 9. Tighten the three front door hinge to body bolts LH side 10. Install the CJB. 1 Position the CJB. 2 Install the nuts. RH side 11. Install the IFS bracket. 1 Position the bracket. 2 Install the bolts. LH and RH sides Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7054 12. Install the A-pillar lower them panel. 1 Position the A-pillar lower trim panel. 2 Install the pin-type retainers. 13. Install the fender. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair FRONT DOOR LATCH REMOVAL 1. Remove the exterior front door handle. 2. Loosen the screw until the door latch remote control is sliding free. 3. Position the interior door handle aside. - Pull to release the clip. 4. Remove and discard the door latch screws. 5. Disconnect the door latch electrical connector. 1 Release the clip. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 7058 2 Disconnect the electrical connector. 6. Remove the door latch assembly. - Slide the door latch remote control towards the front of the vehicle. 7. Remove the three screws and position the anti-theft guard aside. 8. open the clip and disconnect the exterior door handle actuating rod. 9. Disconnect the lock/unlock rod clip. INSTALLATION 1. NOTE: Transfer components as necessary. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair FRONT DOOR TRIM PANEL REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door latch release handle bezel. 1 Remove the screw. 2 Remove the front door latch release handle bezel. 3. Remove the door handle cup screw. 4. Remove the front door trim panel. 1 Remove the screws. 2 Remove the front door trim panel and disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments STRIKER ADJUSTMENT NOTE:Before adjusting the door latch striker plate, verify that the door can be closed easily and fits tightly. 1. Loosen the door latch striker bolts. 2. Reposition the door latch striker plate from side to side or up and down as necessary. 3. Tighten the door latch striker plate bolts. 4. NOTE: The rear door is shown. the front door is similar. Check the adjustment. Repeat the procedure as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair FRONT DOOR WINDOW GLASS REMOVAL 1. Remove the front door trim panel. 2. Remove the screw and the door trim panel bracket. 3. Position the water shield aside. 4. Remove the front door interior glass weatherstrip. 5. Connect the window control switch to the door harness. 6. Connect the battery. 7. Lower the front door window glass to gain access to the screws. 8. Remove the front door window glass screws. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 7068 9. Remove the front door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 7073 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 7074 Front Door Window Motor: Service and Repair FRONT DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. 5. Connect the battery. All vehicles 6. Lower the front door window glass to gain access to the screws. Vehicles with power windows 7. Disconnect the battery. 8. Disconnect the window control switch electrical connector. 9. Remove the front door window glass screws. 10. Support the front door window glass in the full up position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 7075 11. Disconnect the front door power window regulator motor electrical connector. 12. Remove the front door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 13. Remove the front door window regulator assembly. 1 Remove the bolts 2 Remove the nuts. INSTALLATION All vehicles 1. To install, reverse the removal procedure. Cycle the door window glass to make sure of correct door window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair FRONT DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. 5. Connect the battery. All vehicles 6. Lower the front door window glass to gain access to the screws. Vehicles with power windows 7. Disconnect the battery. 8. Disconnect the window control switch electrical connector. 9. Remove the front door window glass screws. 10. Support the front door window glass in the full up position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 7079 11. Disconnect the front door power window regulator motor electrical connector. 12. Remove the front door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 13. Remove the front door window regulator assembly. 1 Remove the bolts 2 Remove the nuts. INSTALLATION All vehicles 1. To install, reverse the removal procedure. Cycle the door window glass to make sure of correct door window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR REAR DOOR HANDLE REMOVAL 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Disconnect the door latch electrical connector. 1 Release the clip. 2 Disconnect the electrical connector. 4. Position the rear door glass top run aside. 1 Remove the bolts. 2 Position the rear door glass top run aside. 5. Disconnect the exterior door handle actuating rod. 1 Open the clip. 2 Disconnect the actuating rod. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 7085 6. Remove the exterior door handle screws. 7. Remove the exterior door handle cover. 1 Pull the exterior door handle. 2 The front of the cover must be released prior to removing. 8. Remove the exterior door handle by sliding towards the rear of the vehicle. 9. Remove the exterior door handle seals. 10. Remove the door latch remote control from inside the door frame. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair INTERIOR DOOR HANDLE REMOVAL 1. Remove the door trim panel. 2. Position the watershield aside. 3. Remove the interior door handle. - Release the clip. 4. Remove the door latch cable. 1 Disconnect the cable conduit. 2 Remove the door latch cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments HINGE ADJUSTMENT - REAR DOOR 1. Remove the front seat safety belt retractor. 2. Mark the positions of the rear door hinges to use as reference points. 3. Loosen the rear door hinge-to-body bolts just enough to permit movement. 4. Loosen the two rear door hinge-to-body bolts just enough to permit movement. 5. Adjust the rear door lo specification. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Page 7092 6. Tighten the four rear door hinge-to-body bolts. 7. Check the front door adjustments. 8. Install the front seat safety belt retractor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair REAR DOOR LATCH REMOVAL 1. Remove the rear door trim panel. 2. Position the water shield aside. 3. Disconnect the door latch electrical connector. 1 Release the clip. 2 Disconnect the electrical connector. 4. Position the rear door glass top run aside. 1 Remove the bolts. 2 Position the door glass top run aside. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 7096 5. Disconnect the exterior door handle actuating rod. 1 Open the clip. 2 Disconnect the actuating rod. 6. Remove and discard the rear door latch screws. 7. Remove the rear door latch. 8. Disconnect the interior door handle cable. 1 Release the cable conduit. 2 Disconnect the cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair REAR DOOR TRIM PANEL REMOVAL 1. Remove the rear door latch release handle bezel. 1 Remove the screw. 2 Remove the rear door latch release handle bezel. 2. Remove the door handle cup screw. 3. Remove the rear door sail panel. 4. Remove the rear door trim panel. - Disconnect the electrical connector. INSTALLATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 7100 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments STRIKER ADJUSTMENT NOTE:Before adjusting the door latch striker plate, verify that the door can be closed easily and fits tightly. 1. Loosen the door latch striker bolts. 2. Reposition the door latch striker plate from side to side or up and down as necessary. 3. Tighten the door latch striker plate bolts. 4. NOTE: The rear door is shown. the front door is similar. Check the adjustment. Repeat the procedure as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REAR DOOR WINDOW GLASS REMOVAL 1. Remove the rear door glass top run. 2. Remove the rear door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left > Page 7111 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Page 7112 Rear Door Window Motor: Service and Repair REAR DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. All vehicles 5. Lower the rear door window glass to gain access to the screws. Vehicles with power windows 6. Disconnect the window control switch electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Page 7113 7. Remove the rear door window glass screws. 8. Support the rear door window glass in the full up position. Vehicles with power windows 9. Disconnect the rear door power window regulator electrical connector. 10. Remove the rear door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 11. Remove the rear door window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Page 7114 INSTALLATION All Vehicles 1. To install, reverse the removal procedure. Cycle the door glass to make sure of correct window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair REAR DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. All vehicles 5. Lower the rear door window glass to gain access to the screws. Vehicles with power windows 6. Disconnect the window control switch electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 7118 7. Remove the rear door window glass screws. 8. Support the rear door window glass in the full up position. Vehicles with power windows 9. Disconnect the rear door power window regulator electrical connector. 10. Remove the rear door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 11. Remove the rear door window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 7119 INSTALLATION All Vehicles 1. To install, reverse the removal procedure. - Cycle the door glass to make sure of correct window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions Hood Latch: Service Precautions CAUTION: Make sure the hood latch is fully engaged. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions > Page 7124 Hood Latch: Service and Repair HOOD LATCH REMOVAL 1. Remove the hood latch nut. 2. NOTE: Mark the hood latch position prior to removal of the bolts. Remove the hood latch bolts. 3. Remove the hood latch. 1 Release the cable conduit. 2 Disconnect the cable. 3 Remove the hood latch. INSTALLATION Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions > Page 7125 1. Connect the hood latch release cable and conduit. 1 Connect the cable. 2 Engage the cable conduit. 2. Position the hood latch with alignment marks and install the bolts. 3. Install the hood latch nut. 4. Verify the hood alignment. 5. Adjust the hood latch. 1 Loosen the bolts. 2 Loosen the nut. 3 Align the hood latch with the hood latch striker. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service Precautions > Page 7126 6. Tighten the hood latch bolts and nut. 7. CAUTION: Make sure the hood latch is fully engaged. Verify the hood latch striker is fully engaging the hood latch. Repeat previous steps as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair HOOD LATCH RELEASE HANDLE REMOVAL 1. Remove the hood latch release handle bolts. 2. Remove the hood latch. 3. Remove the two hood latch release handle cable locators. 4. NOTE: The hood latch release handle cable must be pulled through the dash panel into the passenger compartment. Remove the hood latch release handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7134 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS REMOVAL 1. Open the liftgate glass. 2. Remove the two liftgate nut access covers (one on each side). 3. Disconnect the rear window glass electrical harness connector. 4. Disconnect the heated window grid wire electrical connector. 5. NOTE: An assistant may be needed to carry out this step. Disconnect the two liftgate window glass cylinders. 1 Slide the spring retainer to the end of the socket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 7139 2 Disconnect the socket from the ball stud. 6. NOTE: An assistant may be needed to carry out this step. Remove the two liftgate window glass hinge nuts. INSTALLATION 1. To install, reverse the removal procedure. - Transfer components as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 7143 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair LIFTGATE WINDOW GLASS RELEASE HANDLE REMOVAL 1. Remove the rear window wiper motor. 2. Remove the nuts, striker plate and the liftgate window glass release handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance Technical Service Bulletin # 04C09 Date: 050318 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated January 20, 2004. FSA VIN LIST ACTIVATED: Yes Available through the website by March 21, 2005. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7155 Owner names and addresses will be available March 31, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affect units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that included other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This compliance recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04C09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7156 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. DEALER PRICE For latest prices, refer to DOES II. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIM HANDLING PROCEDURE FOR RETURNING PRIOR LEVEL PARTS Immediate Purge Required: -4L8Z-7843150-DB LATCH ASY - TAILGATE (LIFTGATE) -3L8Z-7843400-FAA HANDLE Prepare and submit a PCS claim as described below: ^ REASON CODE: GB ^ SHIPPER NBR: 04C09 ^ LINE EXPLANATION: Purge Required When preparing your PCS claim, list the part number being returned on the claim, and indicate the quantity of that part number being returned. Your PCS claim must be submitted by March 31, 2005. Claims filed after this date will be denied. Attachment III - Technical Information OVERVIEW This program involves performing specific liftgate latch system repairs on two (2) specific vehicle populations. Each repair procedure identifies the affected vehicles requiring that particular repair. See the list below for specific repairs needed for each vehicle population. 2004 model year Escape vehicles and 2001-2003 Escape vehicles serviced with subject parts: ^ replace the liftgate latch release rod ^ replace release rod clip ^ replace handle assembly return spring and circlip 2005 model year Escape vehicles: ^ replace the liftgate latch release rod ^ replace release rod clip LIFTGATE HANDLE REMOVAL AND REPAIR AFFECTED VEHICLES: 2004 MODEL YEAR ESCAPE VEHICLES AND 2001-2003 MODEL YEAR ESCAPE VEHICLES SERVICED WITH SUBJECT PARTS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7157 1. Open the liftgate. 2. If equipped, remove the rear wiper motor cover. 3. Remove the four (4) screws and remove the liftgate trim panel. 4. Disconnect the liftgate window latch, liftgate handle and liftgate latch release rods by opening the clips. See Figure 1. 5. Release the liftgate window latch ajar switch wiring harness locator and if equipped, disconnect the liftgate latch actuator electrical connector. See Figure 2. 6. Remove the liftgate latch remote control assembly retaining screw and all four (4) retaining nuts. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7158 7. Disconnect the liftgate handle-to-remote release rod from the remote control assembly, then remove the remote control. See Figure 4. 8. Remove the liftgate handle assembly and place it on a bench. See Figure 5. 9. Disassemble the handle as follows: a) Remove the circlip b) Pull the pivot rod out of the handle assembly. c) Note the position of the spring then remove the spring from the handle assembly. 10. NOTE: the new circlip is supplied in the bag with the new spring. Make sure to retain the new circlip for installation to the original pivot rod and handle. LIFTGATE LATCH REMOVAL AND RELEASE ROD REPLACEMENT AFFECTED VEHICLES: ALL VEHICLES COVERED BY 04C09 NOTE: For 2001-2004 model year vehicles, proceed to Step 4. Ford 2005 model year vehicles, begin the repair on step 1. 1. Open the liftgate. 2. If equipped, remove the rear wiper motor cover. 3. Remove the four (4) screws and remove the liftgate trim panel. 4. Disconnect the liftgate ajar switch electrical connector (located on the liftgate latch). 5. Remove the three (3) liftgate latch bolts and retain. 6. Remove the liftgate latch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7159 7. Remove the liftgate latch release rod and install the new rod. See Figure 6. 8. Remove the original release rod clip and replace with the new clip. LIFTGATE LATCH INSTALLATION AFFECTED VEHICLES: ALL VEHICLES COVERED BY 04C09 1. Position the latch assembly in the vehicle. 2. Apply Motorcraft Medium-Strength Threadlocker TA-25 (blue) to the bolts and install the three (3) liftgate latch bolts. See Figure 7. 3. Tight the bolts to 5 Nm (44 lb-in). 4. Connect the liftgate ajar switch electrical connector. NOTE: Fore 2001-2004 model year vehicles, proceed to Liftgate Handle Installation. For 2005 model year vehicles, continue with Step 5 of this procedure. 5. Install the liftgate trim panel and four (4) screws. 6. If equipped, install the rear wiper motor cover. 7. Close the liftgate. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7160 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7161 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7162 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall Liftgate Latch Load Non-Compliance > Page 7163 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Latch: > NHTSA04V602000 > Dec > 04 > Recall 04V602000: Liftgate Latch Release Rod Replacement Trunk / Liftgate Latch: Recalls Recall 04V602000: Liftgate Latch Release Rod Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2005 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 04V602000 RECALL DATE: Dec 17, 2004 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 262113 SUMMARY: Certain 2004-2005 sport utility vehicles and certain 2001-2003 sport utiity vehicles having rear liftgate components serviced with 2004 equivalent components fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 206, "Door Locks and Door Retention Components." The rear liftgate latching system does not meet the inertia load requirement in one direction. CONSEQUENCE: If the liftgate is left unlocked, there is the potential that it may open during a crash. REMEDY: Dealers will replace the rear liftgate latch release rod, the release rod attachment clip and the door handle return spring. The recall is expected to begin on January 24, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 04C09. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. 888-327-4236. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance Technical Service Bulletin # 04C09 Date: 050318 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated January 20, 2004. FSA VIN LIST ACTIVATED: Yes Available through the website by March 21, 2005. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7173 Owner names and addresses will be available March 31, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affect units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that included other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This compliance recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04C09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7174 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. DEALER PRICE For latest prices, refer to DOES II. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIM HANDLING PROCEDURE FOR RETURNING PRIOR LEVEL PARTS Immediate Purge Required: -4L8Z-7843150-DB LATCH ASY - TAILGATE (LIFTGATE) -3L8Z-7843400-FAA HANDLE Prepare and submit a PCS claim as described below: ^ REASON CODE: GB ^ SHIPPER NBR: 04C09 ^ LINE EXPLANATION: Purge Required When preparing your PCS claim, list the part number being returned on the claim, and indicate the quantity of that part number being returned. Your PCS claim must be submitted by March 31, 2005. Claims filed after this date will be denied. Attachment III - Technical Information OVERVIEW This program involves performing specific liftgate latch system repairs on two (2) specific vehicle populations. Each repair procedure identifies the affected vehicles requiring that particular repair. See the list below for specific repairs needed for each vehicle population. 2004 model year Escape vehicles and 2001-2003 Escape vehicles serviced with subject parts: ^ replace the liftgate latch release rod ^ replace release rod clip ^ replace handle assembly return spring and circlip 2005 model year Escape vehicles: ^ replace the liftgate latch release rod ^ replace release rod clip LIFTGATE HANDLE REMOVAL AND REPAIR AFFECTED VEHICLES: 2004 MODEL YEAR ESCAPE VEHICLES AND 2001-2003 MODEL YEAR ESCAPE VEHICLES SERVICED WITH SUBJECT PARTS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7175 1. Open the liftgate. 2. If equipped, remove the rear wiper motor cover. 3. Remove the four (4) screws and remove the liftgate trim panel. 4. Disconnect the liftgate window latch, liftgate handle and liftgate latch release rods by opening the clips. See Figure 1. 5. Release the liftgate window latch ajar switch wiring harness locator and if equipped, disconnect the liftgate latch actuator electrical connector. See Figure 2. 6. Remove the liftgate latch remote control assembly retaining screw and all four (4) retaining nuts. See Figure 3. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7176 7. Disconnect the liftgate handle-to-remote release rod from the remote control assembly, then remove the remote control. See Figure 4. 8. Remove the liftgate handle assembly and place it on a bench. See Figure 5. 9. Disassemble the handle as follows: a) Remove the circlip b) Pull the pivot rod out of the handle assembly. c) Note the position of the spring then remove the spring from the handle assembly. 10. NOTE: the new circlip is supplied in the bag with the new spring. Make sure to retain the new circlip for installation to the original pivot rod and handle. LIFTGATE LATCH REMOVAL AND RELEASE ROD REPLACEMENT AFFECTED VEHICLES: ALL VEHICLES COVERED BY 04C09 NOTE: For 2001-2004 model year vehicles, proceed to Step 4. Ford 2005 model year vehicles, begin the repair on step 1. 1. Open the liftgate. 2. If equipped, remove the rear wiper motor cover. 3. Remove the four (4) screws and remove the liftgate trim panel. 4. Disconnect the liftgate ajar switch electrical connector (located on the liftgate latch). 5. Remove the three (3) liftgate latch bolts and retain. 6. Remove the liftgate latch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7177 7. Remove the liftgate latch release rod and install the new rod. See Figure 6. 8. Remove the original release rod clip and replace with the new clip. LIFTGATE LATCH INSTALLATION AFFECTED VEHICLES: ALL VEHICLES COVERED BY 04C09 1. Position the latch assembly in the vehicle. 2. Apply Motorcraft Medium-Strength Threadlocker TA-25 (blue) to the bolts and install the three (3) liftgate latch bolts. See Figure 7. 3. Tight the bolts to 5 Nm (44 lb-in). 4. Connect the liftgate ajar switch electrical connector. NOTE: Fore 2001-2004 model year vehicles, proceed to Liftgate Handle Installation. For 2005 model year vehicles, continue with Step 5 of this procedure. 5. Install the liftgate trim panel and four (4) screws. 6. If equipped, install the rear wiper motor cover. 7. Close the liftgate. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7178 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7179 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7180 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 04C09 > Mar > 05 > Recall - Liftgate Latch Load Non-Compliance > Page 7181 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > NHTSA04V602000 > Dec > 04 > Recall 04V602000: Liftgate Latch Release Rod Replacement Trunk / Liftgate Latch: All Technical Service Bulletins Recall 04V602000: Liftgate Latch Release Rod Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Escape 2001-2005 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 04V602000 RECALL DATE: Dec 17, 2004 COMPONENT: Latches/Locks/Linkages: Doors: Latch POTENTIAL NUMBER OF UNITS AFFECTED: 262113 SUMMARY: Certain 2004-2005 sport utility vehicles and certain 2001-2003 sport utiity vehicles having rear liftgate components serviced with 2004 equivalent components fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 206, "Door Locks and Door Retention Components." The rear liftgate latching system does not meet the inertia load requirement in one direction. CONSEQUENCE: If the liftgate is left unlocked, there is the potential that it may open during a crash. REMEDY: Dealers will replace the rear liftgate latch release rod, the release rod attachment clip and the door handle return spring. The recall is expected to begin on January 24, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 04C09. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. 888-327-4236. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch LIFTGATE LATCH REMOVAL 1. Remove the liftgate trim panel. 2. Disconnect the liftgate ajar switch electrical connector. 3. Disconnect the liftgate latch actuating rod. 1 Open the clip. 2 Disconnect the actuating rod. 4. Remove and discard the liftgate latch bolts. 5. Remove the liftgate latch. INSTALLATION 1. NOTE: - Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Position the liftgate latch release rod by pushing outboard to remove the slack. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 7188 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control LIFTGATE LATCH REMOTE CONTROL REMOVAL 1. Remove the liftgate trim panel. 2. Disconnect the liftgate latch remote control actuating rods. 1 Open the clip and disconnect the liftgate window latch actuating rod. 2 Open the clip and disconnect the liftgate latch actuating rod. 3. Disconnect the electrical connectors. 1 If equipped, disconnect the liftgate latch actuator electrical connector. 2 Release the liftgate window latch ajar switch wiring harness locator. 4. Remove the liftgate latch remote control assembly. - Remove the screw and nuts. INSTALLATION 1. To install, reverse the removal procedure. - Transfer all necessary components. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 7189 Trunk / Liftgate Latch: Service and Repair Liftgate window Latch LIFTGATE WINDOW LATCH REMOVAL NOTE: Make sure the liftgate window glass is in the raised position. 1. Remove the liftgate trim panel. 2. Disconnect the liftgate window latch. 1 Disconnect the liftgate window latch ajar switch electrical connector. 2 Open the clip and disconnect the actuating rod. 3. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. Remove the liftgate window latch. 1 Remove the bolts. 2 Remove the latch. INSTALLATION 1. Position the liftgate window latch and loosely install the bolts. 2. Adjust the liftgate window latch. - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 7190 3. Tighten the liftgate window latch bolts. 4. Connect the liftgate window latch. 1 Connect the liftgate window latch ajar switch electrical connector. 2 Connect the actuating rod and close the clip. 5. Install the liftgate trim panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair Trunk / Liftgate Solenoid: Service and Repair LIFTGATE LATCH ACTUATOR REMOVAL 1. Remove the liftgate latch remote control. 2. Remove the screws and the liftgate latch actuator. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the wiper pivot arms. 1 Remove the nuts. 2 Remove the wiper pivot arm. 2. Remove the driver side cowl grille. 1 Remove the pin-type retainers. 2 Remove the screw caps and screws. 3 Remove the cowl grille. 3. Remove the passenger side cowl grille. 1 Remove the pin-type retainers. 2 Remove the screw caps and screws. 3 Remove the cowl grille. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Removal and Installation 1. Remove the front wheel and tire assembly. 2. Remove the fender splash shield pin-type retainers. 3. Remove the fender splash shield screws. 4. Remove the fender splash shield. 1 Remove the bolts. 2 Remove the fender splash shield. 5. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7213 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Customer Interest for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7214 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7220 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7221 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7222 Front Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7223 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7224 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7225 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7226 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe: > Page 7227 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7228 Front Subframe: Service and Repair SUBFRAME - FRONT Special Tool(S) Special Tool(s) All vehicles 1. Disconnect the battery ground cable. 2. Remove the rear transmission mount nuts and bolt. 3. Using the special tool, support the engine. 4. Remove the two front wheel and tire assemblies. 5. Remove the two engine air deflectors. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7229 6. Remove the two lower control arm ball joint pinch bolts and nuts (one on each side). 7. Disconnect the stabilizer bar link. 1 Remove the nuts. 2 Disconnect the link from the stabilizer bar. 8. Remove the lateral support crossmember. 1 Remove the belts. 2 Remove the crossmember. 9. Remove the front transmission mount bolt. 10. Remove the engine support crossmember bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7230 11. Remove the nut and the engine support crossmember. 12. Remove the two steering gear bolts. 13. Position the steering gear out of the subframe mounts. 14. Remove the dual converter Y-pipe on the 3.0L (4V) engine or the muffler inlet pipe on the 2.0L (Zetec) engine. Vehicles with manual transmission 15. Remove the two bolts and disconnect the manual transmission shift linkage. Vehicles with 4WD 16. Remove the driveshaft. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Technical Service Bulletins > Page 7231 17. NOTE: Lower the rear of the engine to allow the subframe to clear the companion flange on the transfer case. Lower the rear of the engine approximately 150 mm (6 in). All vehicles 18. CAUTION: Do not allow the rear subframe bolts to come out of the lower control arm bushing. Completely loosen the two front subframe bolts, but do not remove them. 19. NOTE: The lower control arm ball joints must be disconnected from the spindles at the same time the subframe is lowered. With an assistant, remove the two subframe nuts lower the subframe from the vehicle. 20. Transfer all necessary components. 21. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises Front Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises > Page 7240 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame Front/Rear Squeak/Creak Noises > Page 7241 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7247 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7248 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 7249 Front Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 7250 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 7251 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 7252 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 7253 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Subframe Mount: > Page 7254 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7263 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7264 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7270 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7271 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 7272 Rear Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 7273 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 7274 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 7275 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 7276 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe: > Page 7277 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 7278 Rear Subframe: Service and Repair SUBFRAME - REAR Removal Vehicles with 4WD 1. Remove the rear axle assembly. All vehicles 2. Raise and support the vehicle. 3. Remove the four bolts and position the rear control arm aside. 4. Disconnect the exhaust hanger from the subframe. 5. With an assistant, remove the four bolts and rear subframe. Installation All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 7279 1. With an assistant, position the rear subframe and loosely install the bolts. 2. With a 19 mm (0.76 in) rod, align the rear subframe with the alignment holes. 3. Tighten the rear subframe bolts. 4. Connect the exhaust hanger on the subframe. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe > System Information > Technical Service Bulletins > Page 7280 5. Position the four rear control arms in the subframe. - Loosely install the bolts. Vehicles with 4WD 6. Install the rear axle assembly. All vehicles 7. Lower the vehicle. 8. NOTE: The vehicles must be at ride height before tightening the bolts. Tighten the four control arms bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7289 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > Customer Interest for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7290 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7296 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > 10-22-8 > Nov > 10 > Body/Frame - Front/Rear Squeak/Creak Noises > Page 7297 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 7298 Rear Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 7299 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 7300 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 7301 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 7302 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Rear Subframe Mount > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Subframe Mount: > Page 7303 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Console - Floor Console: Description and Operation Console - Floor CONSOLE - FLOOR The high series floor console consists of the following components: - arm rest - floor console finish panel - rear cup holders - storage compartment The low series floor console consists of the following components: - floor console front finish panel - floor console rear finish panel Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Console - Floor > Page 7309 Console: Description and Operation Console - Overhead CONSOLE - OVERHEAD The overhead console may consist of the following components: - garage door opener compartment - lamp switch - roof opening panel control switch (with roof opening panel) - sunglass compartment(s) - center dome lamp/map lamps Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - High Series Console: Service and Repair Floor Console - High Series FLOOR CONSOLE - HIGH SERIES REMOVAL 1. Remove the floor console finish panel. 1 Apply the parking brake. 2 Remove the floor console finish panel. 2. Remove the floor console front bolts. 3. Remove the floor console. 1 Remove the two rear bolts. 2 Remove the floor console. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - High Series > Page 7312 Console: Service and Repair Floor Console - Low Series FLOOR CONSOLE - LOW SERIES REMOVAL 1. Remove the floor console front finish panel. 1 Remove the manual transmission shifter knob by turning counterclockwise. 2 Remove the floor console front finish panel. 2. Remove the floor console rear finish panel. 1 Apply the parking brake. 2 Remove the floor console rear finish panel. 3. Remove the floor console front bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - High Series > Page 7313 4. Remove the floor console. - Remove the rear two bolts and the floor console. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7320 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7321 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7322 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7323 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7324 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7325 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass Headliner: Customer Interest Interior - Headliner Sags at Rear Quarter Glass Article No. 03-25-3 12/22/03 BODY - HEADLINER - SAG/LOOSE AT REAR QUARTER GLASS FORD: 2001-2004 ESCAPE This article supersedes TSB 01-23-7 to update the vehicle model years. ISSUE Some vehicles may exhibit a headliner sag/loose condition at rear quarter glass area near C/D pillar. ACTION Verify condition. Inspect headliner for amount of sag and overall condition. Repair or replace headliner. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE PRIOR TO REPAIRING THE HEADLINER, PLEASE READ THROUGH THE FOLLOWING PROCEDURE IN ITS ENTIRETY. REMEMBER TO INSTALL THE PROTECTIVE TUBING SLEEVE ONTO THE DRILL BIT TO PREVENT DAMAGE TO THE ROOF. DO NOT DRILL THE HOLES UNTIL STEP 12. Prior to repair, inspect the vehicle for the following conditions to determine if the headliner should be replaced: 1. If the headliner sags in excess of 30 mm (1.180 inch) below quarter window black-out paint, the headliner must be replaced (refer to Workshop Manual Section 501). Do not attempt repair. 2. Inspect for delamination of headliner cloth to substrate. If cloth has come loose the headliner must be replaced (refer to Workshop Manual Section 501). Do not attempt repair. If headliner does not meet the above replacement criteria, the headliner can be repaired. Continue with procedure. To repair the headliner, use the Headliner Retainer Installation Kit. ^ For Parchment interior, use part number 2L8Z-78519D80-AAA ^ For Graphite interior, use part number 2L8Z-78519D80-AAB HEADLINER REPAIR PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7334 1. Locate new push-pin holes (See Figure 1 for example locations). 2. Cut template along the curves printed on both sides of template. 3. Make two holes on template along the printed circles. 4. Align template with glass and C-pillar or D-pillar as noted on template. Make sure arrow points to front of the vehicle. Use template for locating proper push-pin spacing (Figure 2). 5. Fit the D-pillar side edge as noted on template and the D-pillar to locate the new push-pin positions between D-pillar and C-pillar (Figure 2). 6. Mark both left-hand side and right-hand side new pin position holes as noted on template. Make sure arrow points to front of the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7335 NOTE DO NOT DRILL AT THIS POINT. ELECTRICAL CONNECTOR AND HARNESS NEED TO BE TEMPORARILY MOVED TO PREVENT DAMAGE. CONNECTOR MUST BE ROTATED 90 DEGREES ON LEFT HAND SIDE ONLY AS VIEWED FROM REAR OF VEHICLE (FIGURE 5). 7. Remove the push-pin and child seat tether cap on left hand side only. This allows headliner to flex and helps prevent crease damage (Figure 3). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7336 8. Remove top portion of left hand D-pillar trim to allow headliner to flex down. Be careful not to bend or over flex headliner too much or creasing will occur (Figure 4). 9. Rotate electrical connector 90 degrees. Pull harness toward rear of vehicle to avoid drill damage (Figure 5). 10. Install protective tubing sleeve onto 7 mm (9/32 inch) drill bit with 7-10 mm of the drill bit exposed beyond the end of the tube (Figure 6). NOTE THIS SLEEVE MUST BE USED TO PREVENT DAMAGE TO THE ROOF. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7337 11. Align drill perpendicular (90 degrees to surface of headliner) so that pin will be flush with headliner surface (Figure 7). NOTE USE SAFETY GLASSES OR GOGGLES TO PROTECT EYES FROM CHIPS WHEN DRILLING HOLES. 12. Drill holes using the 7 mm (9/32 inch) drill bit with protective sleeve. 13. Before inserting the push-pins, remove any debris/metal shavings that have accumulated on the headliner and/or rear cargo department as a result of drilling the holes. NOTE DO NOT INSERT PUSH-PINS YET. 14. Rotate electrical connector and harness to original position. 15. Insert new pins into holes until headliner is 2 mm (.080 inch) above glass blackout line. NOTE BE CAREFUL NOT TO PULL HEADLINER UP TOO FAR. THIS WILL CAUSE GAPPING AT C AND D PILLAR TRIM. PUSH-PINS CAN BE REMOVED AND RE-INSTALLED TO DESIRED LENGTH. 16. Verify electrical function of center dome lamp, rear dome lamp and rear wiper. 17. Install D-pillar trim and push-pins in original locations. Make sure clips and pins are properly positioned and seated. 18. Inspect headliner and trim positioning. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-23-7 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7338 032503A Verify Concern And 2.3 Hrs. Replace Headliner (Includes Time For Overhead Console And Sun/Moon Roof) 032503B Verify Concern And 0.5 Hr. Perform Repair Procedure: DEALER CODING CONDITION BASIC PART NO. CODE 7851944 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass Headliner: All Technical Service Bulletins Interior - Headliner Sags at Rear Quarter Glass Article No. 03-25-3 12/22/03 BODY - HEADLINER - SAG/LOOSE AT REAR QUARTER GLASS FORD: 2001-2004 ESCAPE This article supersedes TSB 01-23-7 to update the vehicle model years. ISSUE Some vehicles may exhibit a headliner sag/loose condition at rear quarter glass area near C/D pillar. ACTION Verify condition. Inspect headliner for amount of sag and overall condition. Repair or replace headliner. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE PRIOR TO REPAIRING THE HEADLINER, PLEASE READ THROUGH THE FOLLOWING PROCEDURE IN ITS ENTIRETY. REMEMBER TO INSTALL THE PROTECTIVE TUBING SLEEVE ONTO THE DRILL BIT TO PREVENT DAMAGE TO THE ROOF. DO NOT DRILL THE HOLES UNTIL STEP 12. Prior to repair, inspect the vehicle for the following conditions to determine if the headliner should be replaced: 1. If the headliner sags in excess of 30 mm (1.180 inch) below quarter window black-out paint, the headliner must be replaced (refer to Workshop Manual Section 501). Do not attempt repair. 2. Inspect for delamination of headliner cloth to substrate. If cloth has come loose the headliner must be replaced (refer to Workshop Manual Section 501). Do not attempt repair. If headliner does not meet the above replacement criteria, the headliner can be repaired. Continue with procedure. To repair the headliner, use the Headliner Retainer Installation Kit. ^ For Parchment interior, use part number 2L8Z-78519D80-AAA ^ For Graphite interior, use part number 2L8Z-78519D80-AAB HEADLINER REPAIR PROCEDURE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7344 1. Locate new push-pin holes (See Figure 1 for example locations). 2. Cut template along the curves printed on both sides of template. 3. Make two holes on template along the printed circles. 4. Align template with glass and C-pillar or D-pillar as noted on template. Make sure arrow points to front of the vehicle. Use template for locating proper push-pin spacing (Figure 2). 5. Fit the D-pillar side edge as noted on template and the D-pillar to locate the new push-pin positions between D-pillar and C-pillar (Figure 2). 6. Mark both left-hand side and right-hand side new pin position holes as noted on template. Make sure arrow points to front of the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7345 NOTE DO NOT DRILL AT THIS POINT. ELECTRICAL CONNECTOR AND HARNESS NEED TO BE TEMPORARILY MOVED TO PREVENT DAMAGE. CONNECTOR MUST BE ROTATED 90 DEGREES ON LEFT HAND SIDE ONLY AS VIEWED FROM REAR OF VEHICLE (FIGURE 5). 7. Remove the push-pin and child seat tether cap on left hand side only. This allows headliner to flex and helps prevent crease damage (Figure 3). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7346 8. Remove top portion of left hand D-pillar trim to allow headliner to flex down. Be careful not to bend or over flex headliner too much or creasing will occur (Figure 4). 9. Rotate electrical connector 90 degrees. Pull harness toward rear of vehicle to avoid drill damage (Figure 5). 10. Install protective tubing sleeve onto 7 mm (9/32 inch) drill bit with 7-10 mm of the drill bit exposed beyond the end of the tube (Figure 6). NOTE THIS SLEEVE MUST BE USED TO PREVENT DAMAGE TO THE ROOF. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7347 11. Align drill perpendicular (90 degrees to surface of headliner) so that pin will be flush with headliner surface (Figure 7). NOTE USE SAFETY GLASSES OR GOGGLES TO PROTECT EYES FROM CHIPS WHEN DRILLING HOLES. 12. Drill holes using the 7 mm (9/32 inch) drill bit with protective sleeve. 13. Before inserting the push-pins, remove any debris/metal shavings that have accumulated on the headliner and/or rear cargo department as a result of drilling the holes. NOTE DO NOT INSERT PUSH-PINS YET. 14. Rotate electrical connector and harness to original position. 15. Insert new pins into holes until headliner is 2 mm (.080 inch) above glass blackout line. NOTE BE CAREFUL NOT TO PULL HEADLINER UP TOO FAR. THIS WILL CAUSE GAPPING AT C AND D PILLAR TRIM. PUSH-PINS CAN BE REMOVED AND RE-INSTALLED TO DESIRED LENGTH. 16. Verify electrical function of center dome lamp, rear dome lamp and rear wiper. 17. Install D-pillar trim and push-pins in original locations. Make sure clips and pins are properly positioned and seated. 18. Inspect headliner and trim positioning. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-23-7 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 03-25-3 > Dec > 03 > Interior - Headliner Sags at Rear Quarter Glass > Page 7348 032503A Verify Concern And 2.3 Hrs. Replace Headliner (Includes Time For Overhead Console And Sun/Moon Roof) 032503B Verify Concern And 0.5 Hr. Perform Repair Procedure: DEALER CODING CONDITION BASIC PART NO. CODE 7851944 07 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 7349 Headliner: Service and Repair HEADLINER REMOVAL Vehicles with overhead console 1. Remove the overhead console. 1 Open the front console door. 2 Remove the screws. 3 Remove the overhead console. If equipped, disconnect the electrical connector. All vehicles 2. Remove the two sun visors and two clips. 1 Remove the six screws. 2 Remove the two sun visors and two clips. If equipped, disconnect the electrical connector. 3. Remove the eight passenger assist handle covers. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 7350 4. Remove the four passenger assist handles. 1 Remove the eight bolts. 2 Remove the four passenger assist handles. 5. Open the four A-pillar passenger assist handle covers. 6. Remove the two A-pillar passenger assist handles. 1 Remove the four bolts. 2 Remove the two A-pillar passenger assist handles. 7. Remove the two windshield side garnish mouldings. 8. If equipped, remove the roof opening panel moulding. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 7351 9. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-Ring cover does not remain in place, install a new cover. Remove the two safety belt D-ring covers. 10. Remove the two safety belt D-ring bolts. 11. Position the front and rear door weatherstrips aside. 12. Remove the upper B-pillar trim panels. 13. Remove the two C-pillar trim panels. 14. Remove the two D-pillar trim panels. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 7352 15. Remove the front interior lamp lens. 16. Remove the front interior lamp. 1 Remove the screws. 2 Remove the front interior lamp. Disconnect the electrical connector. 17. Remove the rear interior lamp. - Disconnect the electrical connector. 18. Remove the five pin-type retainers. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 7353 19. If equipped, remove the three child seat tether anchor covers. 20. If equipped, remove the three bolts and the child seat tether anchors. 21. Remove the headliner. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel Trim Panel: Service and Repair B-Pillar Trim Panel B-PILLAR TRIM PANEL REMOVAL 1. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-ring cover does not remain in place, install a new cover. Remove the safety belt D-ring cover. 2. Remove the safety belt D-ring bolt. 3. Position the front and rear door weatherstrips aside. 4. Remove the upper B-pillar trim panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 7358 5. Remove the front door scuff plate trim panel. 1 Remove the pin-type retainers. 2 Remove the front door scuff plate trim panel. 6. Remove the rear door scuff plate trim panel. 1 Remove the pin-type retainers. 2 Remove the rear door scuff plate trim panel. 7. Remove the lower B-pillar trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 7359 Trim Panel: Service and Repair C-Pillar Trim Panel C-PILLAR TRIM PANEL REMOVAL LH side 1. If equipped with a power point on the LH quarter trim panel, disconnect the battery ground cable. Both sides 2. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-ring cover does not remain in place, install a new cover. Remove the safety belt D-ring cover. 3. Remove the safety belt D-ring bolt. 4. Remove the pin-type retainers and the liftgate scuff plate trim panel. 5. Position the liftgate weatherstrip aside. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 7360 6. if equipped, remove the cargo net hold-down. 7. Remove the rear quarter trim panel. 1 Insert a tape-wrapped screwdriver between the D-pillar trim panel and rear quarter trim panel. 2 Push the screwdriver in the direction of the arrow and remove the rear quarter trim panel. 8. If equipped, disconnect the accessory socket connector (left side). 9. Remove the C-pillar trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. NOTE: Make sure the window glass is in the raised position. Remove the exterior front door latch. 2. Remove the door lock cylinder. 1 Release the clips. 2 Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 7371 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 7372 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair REMOTE TRANSMITTER PROGRAMMING NOTE: - All keyless entry remote transmitters must be programmed at the same time. - All previous transmitter identification codes (TIC's) will be erased when programming mode is entered. - To program (or reprogram) the keyless entry remote transmitters into the generic electronic module (GEM), carry out the following steps. 1. Turn the ignition from OFF to RUN eight times within 10 seconds, ending in RUN. If the GEM has successfully entered program mode, it will lock and unlock all the doors. 2. NOTE: The first TIC must be entered within 7.5 seconds of entering the program mode and additional TICs must be entered within 7.5 seconds of the first TIC. The programming mode is exited whenever the timing constraints are not met. Press any button on a keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait for several seconds and press the button again. 4. Turn the ignition switch to the OFF position, or wait up to five minutes after step 1, to exit program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the GEM will lock and unlock all the doors one last time. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations View 151-35 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front > Page 7385 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front > Page 7386 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Unit, Driver Side Front > Page 7387 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Application and ID Power Door Lock Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Master Window/Door Lock/Unlock Switch View 151-34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Master Window/Door Lock/Unlock Switch > Page 7395 View 151-33 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 7398 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7401 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7402 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7403 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7408 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7409 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7410 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7411 Exterior Rear View Mirror Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips Paint: Technical Service Bulletins Paint - Plastic Bumper/Fascia Service Tips Article No. 03-10-1 PAINT - PLASTIC BUMPER/FASCIA PARTS - PREPARATION PROCEDURES - SERVICE TIPS FORD: 2002-2003 CROWN VICTORIA, FOCUS, MUSTANG, TAURUS, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, WINDSTAR LINCOLN: 2002 CONTINENTAL 2002-2003 LS, TOWN CAR, NAVIGATOR MERCURY: 2002-2003 COUGAR, GRAND MARQUIS, SABLE 2002 VILLAGER 2002-2003 MOUNTAINEER ISSUE This article is being written to clarify the proper procedures to prepare plastic fascia parts. Multiple repair procedures for painting plastic fascia parts are being used in the field that are inconsistent and may not provide adequate paint adhesion. Paint companies repair procedures are system specific and do not lend themselves to generic repair procedures. ACTION Follow the repair information in this TSB flow chart to perform the initial steps for fascia paint repair only. After completing the flow chart refer to paint company system recommendations for materials and mixing instructions for the type of plastic being painted. Also listed in this TSB are some important service tips to remember when preparing plastic parts for paint application. SERVICE INFORMATION For repair information, refer to flow chart Figure 1. Additional Service Tips: - When washing plastic parts use Motorcraft Detail Wash (ZC-3-A) mixed at a ratio (1 oz. of ZC-3-A) to 1 gallon of water. - Use basecoat reducer for a wipe test on coated service parts. - If the coating (adhesion promoter/primer) shrivels or lifts, remove only that layer of material by Scotchbrite scuffing or machine sanding. Never remove material to bare plastic substrate, as this will create more work in order to protect the substrate for application of paint. - If the adhesion promoter or primer is intact, use a gray Scotchbrite pad and scuff the entire part to continue preparation steps for normal paint application. - Follow paint company recommendations for primer or basecoat application. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7417 Paint: Technical Service Bulletins Paint - Approved Paint Materials Article No. 02-16-7 BODY-PAINT-APPROVED PAINT MATERIALS FOR WARRANTY REPAIRS FORD: 2003 CROWN VICTORIA, FOCUS, MUSTANG, TAURUS, E SERIES, ESCAPE, EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, WINDSTAR, F-650, F-750 LINCOLN: 2003 CONTINENTAL, LS, TOWN CAR, AVIATOR, NAVIGATOR MERCURY: 2003 COUGAR, GRAND MARQUIS, SABLE, MOUNTAINEER ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested ten major refinish paint suppliers materials for warranty repairs. Tests were conducted to paint material specification WSS-M2P100-D for refinish paint materials. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7418 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7419 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7420 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7421 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7422 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7423 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7424 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7425 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7426 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7427 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7428 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7429 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7430 ACTION The materials listed in the Figures 1-13, are approved paint systems for refinishing service parts as well as repair of steel and plastic OEM paint systems. OTHER APPLICABLE ARTICLES: 98-18-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7431 Paint: Technical Service Bulletins Paint - New Polishing Products and Procedures Article No. 02-16-3 PAINT-NEW POLISHING PRODUCTS-SERVICE PROCEDURES FORD: 2002-2003 CROWN VICTORIA, ESCORT, FOCUS, TAURUS, ESCAPE, EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 LINCOLN: 2002-2003 LS, TOWN CAR, NAVIGATOR MERCURY: 2002-2003 GRAND MARQUIS, SABLE, MOUNTAINEER ISSUE Vehicles that have small scratches, mars, dirt, and scuff marks found during pre-delivery or reconditioning may be repaired without repainting using new Motorcraft polishing products. These products may also be used effectively for collision damage repairs. ACTION Read this TSB in its entirety BEFORE beginning any repairs. Repair as outlined in the following Service Procedures. BACKGROUND The OEM paint system has changed significantly the last 18 months. Previous paint systems required a number days to be fully cured. The OEM paint system used today cures faster and is also much harder. The hardness of the OEM system is similar to the hardness of current Refinish paint system and as a result, a new polishing system is necessary. These products have been tested on all Ford Motor Company OEM paint finishes and all Major Refinish paint brands. The system has significantly better results than all other products tested for OEM and Refinish paint systems. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS IS MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, FIELD SERVICE ACTIONS, CUSTOMER SATISFACTION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY OR ESP/ESC, OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE, (I.E., EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE: ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. SERVICE PROCEDURE 1. Make sure the area to be polished is clean and free of paint sealants and waxes. 2. To remove dirt nibs, runs, or sags, sand the surface with a D.A. sander or by hand with P1500 grit sandpaper. 3. Apply the Motorcraft ZC-39-B backing pad to dual action sander. 4. Apply the Motorcraft polishing disc (ZC-39-A kit) to the D.A. sander. NOTE MAKE SURE THE POLISHING DISC IS CENTERED EXACTLY ON THE BACKING PAD, OR "WILD SCRATCHES" MAY OCCUR. 5. Dampen the polishing disc with water from a spray bottle before use. 6. Damp polish the repair area until the dirt, mar, etc. has been removed. The surface should now be semi-polished. NOTE IF THE IMPERFECTION CANNOT BE REMOVED WITH THE POLISHING DISC, HAND SAND WITH FINE SAND PAPER IN A STEP PROCESS (I.E. 600 GRIT, 1200 GRIT, 1500 GRIT). THE POLISHING DISC WILL ONLY REMOVE 1500 GRIT SCRATCHES AND HIGHER. 7. To remove the sand scratches and also remove swirl marks, install a foam-polishing pad onto a buffer. 8. Apply a small amount of the Motorcraft Finish Enhancement Compound on the foam pad for the first time of pad use. Do not use a wool pad with this product. 9. Move the pad around in a 2 foot area to spread out the material, then start up the buffer. Recommended speed is 1750 rpm. Apply medium pressure and let the polisher do the work. Verify the imperfection has been removed. If not, repeat Step 9 until complete. 10. Wipe the repair area with a detailing cloth to complete the repair. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 7432 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes The upper portion of the vehicle certification (VC) label contains the manufacturer's name, the month and year of manufacture, the certification statement and the VIN. It also includes gross vehicle weight ratings (GVWR). The VC label is located on the left-hand front door jamb. The first set of numbers/letters indicate the vehicle primary body color code. The second set of numbers/letters (if applicable), indicate a lower body, two-tone paint code. - BZ Chrome Yellow - C2 Gold Ash Metallic - CX Dark Shadow Gray (clearcoat) - DV Light Tundra - FX Merlot - G2 Redfire - L2 True Blue Pearl (clearcoat) - P5 Aspen Green Metallic Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7435 - TL Satin Silver (clearcoat) - UA Ebony (clearcoat) - YZ Oxford White (clearcoat) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7436 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Application and ID Power Door Lock Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Passenger Side Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Passenger Side Front > Page 7448 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7449 Seat Heater Control Module: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so may result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7450 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so may result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7451 - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Remove the front seat. 2. Remove the heated seat module. - Disconnect the electrical connector. - Using a small flat-blade screwdriver, release the locking tab and slide the module off the bracket. INSTALLATION WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar climate controlled heated power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition install the original part and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7452 carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Install the heated seat module. - Slide the heated seat module down over the attachment bracket until the locking tab snaps into place. - Connect the electrical connector. 2. Install the front seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7453 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7457 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7458 Sunroof / Moonroof Module: Service and Repair ROOF OPENING PANEL MODULE REMOVAL 1. Remove the headliner. 2. Remove the root opening panel module 1 Disconnect the electrical connector. 2 Remove the screw. 3 Remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 7464 Sunroof / Moonroof Motor: Service and Repair ROOF OPENING PANEL MOTOR REMOVAL 1. Close the roof opening panel. 2. Remove the headliner. 3. Remove the roof opening panel motor. 1 Disconnect the electrical connectors. 2 Remove the bolts. 3 Remove the roof opening panel motor. INSTALLATION 1. NOTE: The roof opening panel should be in the closed position. Connect the roof opening panel motor electrical connector. 2. With the motor still removed, bump the roof opening panel switch one time only towards the close or vent open position. 3. Install the roof opening panel motor. 1 Position the roof opening panel motor 2 Install the bolts. 4. Check for correct operation of the roof opening panel motor. 5. Install the headliner. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch > Page 7469 View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch > Page 7472 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair AIR DEFLECTOR REMOVAL 1. Open the roof opening panel. 2. Remove the roof opening panel frame. 3. Remove the air deflector. - Lift up the air deflector and slide the air deflector to the rear to release the air deflector arms. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Roof Opening Panel Front Drain Hose Sunroof / Moonroof Drain: Service and Repair Roof Opening Panel Front Drain Hose ROOF OPENING PANEL FRONT DRAIN HOSE REMOVAL Passenger side 1. Remove the instrument panel. All 2. Remove the headliner. 3. Disconnect the roof opening panel front drain hose at the front body pillar. 4. Remove the roof opening panel front drain hose. 1 Disconnect the roof opening panel front drain hose from the roof opening panel frame. 2 Remove the roof opening panel front drain hose. - Remove the tape securing the roof opening panel front drain hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Roof Opening Panel Front Drain Hose > Page 7480 Sunroof / Moonroof Drain: Service and Repair Roof Opening Panel Rear Drain Hose ROOF OPENING PANEL REAR DRAIN HOSE REMOVAL 1. Remove the headliner. 2. Disconnect the roof opening panel rear drain hose. 3. Remove the roof opening panel rear drain hose. 1 Disconnect the roof opening panel rear drain hose from the roof opening panel frame. 2 Remove the roof opening panel rear drain hose. - Remove the tape securing the roof opening panel drain hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair ROOF OPENING PANEL FRAME REMOVAL 1. Remove the headliner. 2. Disconnect the in-line electrical connector. 3. Disconnect the four roof opening panel drain hoses. 4. Release the wire harness locators. 5. Remove the roof opening panel frame. 1 Remove the eight roof opening panel frame bolts. 2 Remove the roof opening panel frame. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 7484 INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7488 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7489 Sunroof / Moonroof Module: Service and Repair ROOF OPENING PANEL MODULE REMOVAL 1. Remove the headliner. 2. Remove the root opening panel module 1 Disconnect the electrical connector. 2 Remove the screw. 3 Remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Rear Height Motor Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Rear Height Motor > Page 7495 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Rear Height Motor > Page 7496 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7500 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7501 Power Seat Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7502 Power Seat Switch: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7503 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7504 Power Seat Switch: Service and Repair SEAT CONTROL SWITCH REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic toot must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Disconnect the battery ground cable. 2. Remove the seat control switch knob. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 7505 3. Remove the front seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - Disconnect the electrical connector(s). 4. Remove the seat control switch 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information Seat Cushion: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Failure to follow these instructions may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information > Page 7510 Seat Cushion: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Seat Cushion: Service and Repair Front Seat Driver Seat FRONT SEAT CUSHION - DRIVER SEAT Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Failure to follow these instructions may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety bell pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7513 the restraint system diagnostic tool must be installed in the side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. - Manual seat shown. power seat similar. All vehicles 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side air bag 3. Disconnect the driver seat side air bag module electrical connector. 4. Connect the special tool to the driver seat side air bag module body harness electrical connector. All vehicles 5. Disconnect the driver safety belt pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7514 6. Connect the special tool to the driver safety belt pretensioner body harness electrical connector. 7. Disconnect the passenger safety belt pretensioner electrical connector. 8. Connect the special tool to the passenger safety belt pretensioner body harness electrical connector. Vehicles with side air bag 9. Disconnect the passenger side air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7515 10. Connect the special tool to the passenger side air bag module body harness electrical connector. All vehicles 11. Lower the glove compartment. - Press the locking tabs. 12. Disconnect the passenger air bag module electrical connector. 13. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 14. Lower the driver air bag connector access cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7516 15. Disconnect the driver air bag module electrical connector. 16. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 17. Connect the battery ground cable. 18. Prove out the air bag system. 19. Remove the seat track-to-floor nuts. 20. Position the driver seat rearward. 21. If equipped with power seats, disconnect the negative battery cable. 22. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Remove the driver seat. 1 Remove the seat track-to-floor bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7517 2 Remove the driver seat. - If equipped with power seats, disconnect the electrical connector. 23. Disconnect the seat cushion trim cover J-clips. 24. Remove the front seat cushion trim and pad from the front seat cushion frame. - If equipped with heated seats, disconnect the backrest heated grid and the seat cushion heated grid electrical connectors. 25. Separate the front seat cushion trim from the front seat cushion pad. ASSEMBLY WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of all accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Failure to follow these instructions may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7518 NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag-to-floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. All vehicles 1. Install the front seat cushion trim to the front seat cushion pad. 2. Install the front seat cushion trim and pad to the front seat cushion frame. - If equipped with heated seats, connect the backrest heated grid and the seat cushion heated grid electrical connectors. 3. Connect the seat cushion trim cover J-clips. 4. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Install the driver seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7519 1 Position the driver seat. 2 Install the seat track-to-floor bolts. - If equipped with power seats, connect the electrical connector. 5. If equipped with power seats, connect the battery ground cable. 6. Position the driver seat forward. 7. Install the seat track-to-floor nuts. 8. If equipped with power seats. disconnect the battery ground cable and wait one minute. Vehicles with side air bag 9. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Remove the special tool from the driver side air bag module body harness electrical connector. 10. Connect the driver side air bag module electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7520 11. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Remove the special tool from the driver safety belt pretensioner body harness electrical connector. 12. Connect the driver safety belt pretensioner electrical connector. 13. Connect the battery ground cable. 14. With the remaining special tools still in place, prove out the air bag system. 15. Disconnect the battery ground cable and wait at least one minute. 16. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Remove the special tool from the passenger safety belt pretensioner body harness electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7521 17. Connect the passenger safety belt pretensioner electrical connector. Vehicles with side air bag 18. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Remove the special tool from the passenger side air bag module body harness electrical connector. 19. Connect the passenger side air bag module electrical connector. All vehicles 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7522 injury. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 21. Connect the passenger air bag module electrical connector. 22. Raise the glove compartment. - Press the locking tabs. 23. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. Remove the special tool from the steering column harness side of the driver air bag module electrical connector. 24. Connect the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7523 25. Install the driver air bag connector access cover. 26. Connect the battery ground cable. 27. Prove out the air bag system. Passenger Seat FRONT SEAT CUSHION - PASSENGER SEAT Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safely standards. Failure to follow these instructions may result in personal injury. NOTE: - If a seat equipped with a seat mounted side air bag system is being repaired the air bag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnosis/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7524 the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. All vehicles 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side air bag 3. Disconnect the passenger side air bag module electrical connector. 4. Connect the special tool to the passenger side air bag module body harness electrical connector. All vehicles 5. Disconnect the passenger safety belt pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7525 6. Connect the special tool to the passenger safety belt pretensioner body harness electrical connector. 7. Disconnect the driver safety belt pretensioner electrical connector. 8. Connect the special tool to the driver safety belt pretensioner body harness electrical connector. Vehicles with side air bag 9. Disconnect the driver side air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7526 10. Connect the special tool to the driver side air bag module body harness electrical connector. All vehicles 11. Lower the driver air bag connector access cover. 12. Disconnect the driver air bag module electrical connector. 13. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 14. Lower the glove compartment. - Press the locking tabs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7527 15. Disconnect the passenger air bag module electrical connector. 16. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 17. Connect the battery ground cable. 18. Prove out the air bag system. 19. Remove the seat track to floor nuts. 20. Position the passenger seat rearward. 21. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Remove the passenger seat. 1 Remove the seat track to floor bolts. 2 Remove the passenger seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7528 - If equipped with heated seats, disconnect the electrical connector. 22. Disconnect the seat cushion trim cover J-clips. 23. Remove the front seat cushion trim and pad from the front seat cushion frame. - If equipped with heated seats, disconnect the backrest heated grid connector and the seat cushion heated grid electrical connector from the seat wiring harness. 24. Separate the front seat cushion trim from the front seat cushion pad. ASSEMBLY WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collusion, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Failure to follow these instructions may result in personal injury. NOTE: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7529 - If a seat equipped with a seat mounted side air bag system is being repaired the air bag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. All vehicles 1. Install the front seat cushion trim to the front seat cushion pad. 2. Install the front seat cushion trim and pad to the front seat cushion frame. - If equipped with heated seats, connect the backrest heated grid connector and the seat cushion heated grid electrical connector to the seat wiring harness. 3. Connect the seat cushion trim cover J-clips. 4. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7530 Install the passenger seat. 1 Position the passenger seat. 2 Install the seat track to floor bolts. - If equipped with heated seats, connect the electrical connector. 5. Position the passenger seat forward. 6. Install the seat track to floor nuts. 7. Disconnect the battery ground cable and wait at least one minute. Vehicles with side air bag 8. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in injury and possible violation of vehicle safety standards. Remove the special tool from the passenger side air bag module body harness electrical connector. 9. Connect the passenger air bag module electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7531 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in injury and possible violation of vehicle safety standards. Remove the special tool from the passenger safety belt pretensioner body harness electrical connector. 11. Connect the passenger safety belt pretensioner electrical connector. 12. Connect the battery ground cable. 13. With the remaining special tools still in place, prove out the air bag system. 14. Disconnect the battery ground cable and wait at least one minute. 15. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in injury and possible violation of vehicle safety standards. Remove the special tool from the driver safety belt pretensioner body harness electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7532 16. Connect the driver safety belt pretensioner electrical connector. Vehicles with side air bag 17. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in injury and possible violation of vehicle safety standards. Remove the special tool from the driver side air bag module body harness electrical connector. 18. Connect the driver side air bag module electrical connector. All vehicles 19. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in injury and possible violation of vehicle safety standards. Remove the special tool from the steering column harness side of the driver air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7533 20. Connect the driver air bag module electrical connector. 21. Install the driver air bag connector access cover. 22. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in injury and possible violation of vehicle safety standards. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 23. Connect the passenger air bag module electrical connector. 24. Raise the glove compartment. - Press the locking tabs. 25. Connect the battery ground cable. 26. Prove out the air bag system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7534 Seat Cushion: Service and Repair Rear Seat REAR SEAT CUSHION DISASSEMBLY NOTE: 60% split bench seat shown, 40% and bench seat similar. 1. Lift up the rear seat cushion. 2. Remove the rear seat cushion. - Pull up on release lever and slide the seat out of the floor bracket. 3. Release the J-retainer. 4. Unzip the rear seat cushion trim. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat > Page 7535 5. Remove the rear seat cushion trim from the rear seat cushion pad. 6. Remove the rear seat cushion bracket. 1 Remove the two bolts. 2 Remove the rear seat cushion bracket ASSEMBLY 1. To assemble, reverse the disassembly procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7540 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7541 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7542 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7543 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7544 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7545 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7546 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7547 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7548 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7549 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7550 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7551 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7552 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7553 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7554 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7555 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7556 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7557 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7558 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7559 Seat Heater: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7560 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7561 Seat Heater: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 119-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7562 Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Passenger Side Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Passenger Side Front > Page 7567 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7568 Seat Heater Control Module: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so may result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7569 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so may result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7570 - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Remove the front seat. 2. Remove the heated seat module. - Disconnect the electrical connector. - Using a small flat-blade screwdriver, release the locking tab and slide the module off the bracket. INSTALLATION WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar climate controlled heated power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition install the original part and Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7571 carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Install the heated seat module. - Slide the heated seat module down over the attachment bracket until the locking tab snaps into place. - Connect the electrical connector. 2. Install the front seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 7572 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Side Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Side > Page 7577 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7578 Seat Heater Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7579 Seat Heater Switch: Service and Repair HEATED SEAT SWITCH REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Disconnect the battery ground cable. 2. Remove the seat control switch knob. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7580 3. Remove the front seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - Disconnect the electrical connectors. 4. Release the locking tab and remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair REAR SEAT BACKREST LATCH REMOVAL 1. Remove the rear seat backrest. 2. Remove the rear seat backrest side trim panel. 3. Remove the rear seat backrest latch. 1 Remove the bolt. 2 Remove the nut. 3 Remove the latch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information Seat Track: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling all air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or test to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information > Page 7588 Seat Track: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat Seat Track: Service and Repair Driver Seat SEAT TRACK - DRIVER SEAT Special Tool(s) SPECIAL TOOLS REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7591 the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. - Manual seat track shown, power seat track similar. All vehicles 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side air bag 3. Disconnect the driver side air bag module electrical connector. 4. Connect the special tool to the driver side air bag module body harness electrical connector. All vehicles 5. Disconnect the driver safety belt pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7592 6. Connect the special tool to the driver safety belt pretensioner body harness electrical connector. 7. Disconnect the passenger safety belt pretensioner electrical connector. 8. Connect the special tool to the passenger safety belt pretensioner body harness electrical connector. Vehicles with side air bag 9. Disconnect the passenger side air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7593 10. Connect the special tool to the passenger side air bag module body harness electrical connector. All vehicles 11. Lower the glove compartment. - Press the locking tabs. 12. Disconnect the passenger air bag module electrical connector. 13. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 14. Lower the driver air bag connector access cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7594 15. Disconnect the driver air bag module electrical connector. 16. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 17. Connect the battery ground cable. 18. Prove out the air bag system. 19. Remove the seat track to floor nuts. 20. Position the driver seat rearward. 21. If equipped with power seats, disconnect the negative battery cable. 22. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Remove the driver seat. 1 Remove the seat track to floor bolts. 2 Remove the driver seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7595 - If equipped with power seats, disconnect the electrical connector. 23. If equipped, remove the seat height adjustment control. 24. Remove the outboard seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - If equipped with a power/heated seat, disconnect the electrical connector(s). 25. Remove the inboard seat cushion side shield. 26. Remove the front seat backrest bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7596 27. NOTE: If equipped with a side air bag module, note the routing of the wiring harness for installation. Remove the front seat backrest. 1 Remove the pivot nut. 2 Remove the backrest. - If equipped with heated seats, disconnect the backrest heated grid electrical connector. 28. Disconnect the seat cushion trim cover J-clips. 29. Remove the front seat cushion trim and pad from the front seat cushion frame. - If equipped with heated seats, disconnect the seat cushion heated grid electrical connector from the seat wiring harness. 30. Remove the front seat cushion pan. 1 Remove the bolts. 2 Remove the front seat cushion pan. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7597 31. If equipped with manual seats, remove the seat adjuster. - Unclip the seat adjuster pins. 32. NOTE: Note the routing of the wiring harness for installation. Remove the safety belt pretensioner from the seat track. 1 Remove the bolt. 2 Remove the safety belt pretensioner. INSTALLATION WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the ail bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7598 NOTE: - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. All vehicles 1. Install the safety belt pretensioner. 1 Position the safety belt pretensioner. 2 Install the bolt. 2. If equipped with manual seats, install the seat adjuster. - Connect the seat adjuster pins. 3. Install the front seat cushion pan. 1 Position the front seat cushion pan. 2 Install the bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7599 4. Install the front seat cushion trim and pad to the front seat cushion frame. - If equipped with heated seats, connect the seat cushion heated grid electrical connector to the seat wiring harness. 5. Connect the seat cushion trim cover J-clips. 6. Install the front seat backrest. 1 Install the backrest. 2 Install the pivot nut. 7. Install the front seat backrest bolts. - If equipped with heated seats, connect the backrest heated grid electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7600 8. Install the inboard seat cushion side shield. 9. Install the outboard seat cushion side shield. - If equipped with a power/heated seat, connect the electrical connector. 1 Install the shield. 2 Install the screw. 3 Install the seat backrest handle. 10. If equipped, install the seat height adjustment control. 11. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Install the driver seat. 1 Position the driver seat. 2 Install the seat track to floor bolts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7601 - If equipped with power seat, connect the electrical connector. 12. If equipped with power seats, connect the battery ground cable. 13. Position the driver seat forward. 14. Install the seat track to floor nuts. 15. If equipped with power seats, disconnect the battery ground cable and wait one minute. Vehicles with side air bag 16. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the driver side air bag module body harness electrical connector. 17. Connect the driver side air bag module electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7602 18. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the driver side safety belt pretensioner body harness electrical connector. 19. Connect the driver safety belt pretensioner electrical connector. 20. Connect the battery ground cable. 21. With the remaining special tools still in place, prove out the air bag system. 22. Disconnect the battery ground cable and wait at least one minute. 23. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the passenger safety belt pretensioner body harness electrical connector. 24. Connect the passenger safety belt pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7603 Vehicles with side air bag 25. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the passenger side air bag module body harness electrical connector. 26. Connect the passenger side air bag module electrical connector. All vehicles 27. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7604 28. Connect the passenger air bag module electrical connector. 29. Raise the glove compartment. - Press the locking tabs. 30. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the steering column harness side of the driver air bag module electrical connector. 31. Connect the driver air bag module electrical connector. 32. Install the driver air bag connector access cover. 33. Connect the battery ground cable. 34. Prove out the air bag system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7605 Seat Track: Service and Repair Passenger Seat SEAT TRACK - PASSENGER SEAT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag system is being repaired the air bag system must be deactivated as per the deactivation procedure contained in Air Bag Systems. - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7606 - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. All vehicles 1. Position the front seats forward. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side air bag 3. Disconnect the passenger side air bag module electrical connector. 4. Connect the special tool to the passenger side air bag module body harness electrical connector. All vehicles 5. Disconnect the passenger safety belt pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7607 6. Connect the special tool to the passenger safety belt pretensioner body harness electrical connector. 7. Disconnect the driver safety belt pretensioner electrical connector. 8. Connect the special tool to the driver safety belt pretensioner body harness electrical connector. Vehicles with side air bag 9. Disconnect the driver side air bag module electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7608 10. Connect the special tool to the driver side air bag module body harness electrical connector. All vehicles 11. Lower the driver air bag connector access cover. 12. Disconnect the driver air bag module electrical connector. 13. Connect the special tool to the steering column harness side of the driver air bag module electrical connector. 14. Lower the glove compartment. - Press the locking tabs. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7609 15. Disconnect the passenger air bag module electrical connector. 16. Connect the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 17. Connect the battery ground cable. 18. Prove out the air bag system. 19. Remove the seat track to floor nuts. 20. Position the passenger seat rearward. 21. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Remove the passenger seat. 1 Remove the seat track to floor bolts. 2 Remove the passenger seat. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7610 - If equipped with heated seats, disconnect the heated seat electrical connector. 22. Remove the outboard seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - If equipped with heated seats, disconnect the electrical connector. 23. Remove the inboard seat cushion side shield. 24. Remove the front seat backrest bolts. 25. NOTE: If equipped with a side air bag module, note the routing of the wiring harness for installation. Remove the front seat backrest. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7611 1 Remove the pivot nut. 2 Remove the backrest. - If equipped with heated seats, disconnect the backrest heated grid electrical connector. 26. If equipped, remove the under seat storage bin. 27. Disconnect the seat cushion trim cover J-clips. 28. Remove the front seat cushion trim and pad from the front seat cushion frame. - If equipped with heated seats, disconnect the seat cushion heated grid electrical connector. 29. Remove the front seat cushion pan. 1 Remove the bolts. 2 Remove the front seat cushion pan. 30. Remove the seat adjuster. - Unclip the seat adjuster pins. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7612 31. NOTE: Note the routing of the wiring harness for installation. Remove the safety belt pretensioner. 1 Remove the bolt. 2 Remove the safety belt pretensioner. INSTALLATION WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag system is being repaired the air bag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Restraint system diagnostic tools must be installed under the seats in the side air bag to floor connector. - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7613 All vehicles 1. Install the safety belt pretensioner. 1 Install the safety belt pretensioner. 2 Install the bolt. 2. Install the seat adjuster. - Connect the seat adjuster pins. 3. Install the front seat cushion pan. 1 Position the front seat cushion pan. 2 Install the bolts. 4. Install the front seat cushion and pad to the front seat cushion frame. - If equipped with heated seats, connect the seat cushion heated grid electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7614 5. Connect the seat cushion trim cover J-clips. 6. If equipped, install the under seat storage bin. 7. Install the front seat backrest. 1 Install the backrest. 2 Install the pivot nut. 8. Install the front seat backrest bolts. - If equipped with heated seats, connect the backrest heated grid electrical connectors. 9. Install the inboard seat cushion side shield. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7615 10. Install the outboard seat cushion side shield. - If equipped with heated seats, connect the electrical connector. 1 Install the shield. 2 Install the screw. 3 Install the seat backrest handle. 11. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Install the passenger seat. 1 Position the passenger seat. 2 Install the seat track to floor bolts. - If equipped with heated seats, connect the heated seat connector. 12. Position the passenger seat forward. 13. Install the seat track to floor nuts. Vehicles with side air bag Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7616 14. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the passenger side air bag module body harness electrical connector. 15. Connect the passenger side air bag module electrical connector. All vehicles 16. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the passenger safety belt pretensioner body harness electrical connector. 17. Connect the passenger safety belt pretensioner electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7617 18. Connect the battery ground cable. 19. With the remaining special tools still in place, prove out the air bag system. 20. Disconnect the battery ground cable and wait at least one minute. 21. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the driver safety belt pretensioner body harness electrical connector. 22. Connect the driver safety belt pretensioner electrical connector. Vehicles with side air bag 23. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the driver side air bag module body harness electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7618 24. Connect the driver side air bag module electrical connector. All vehicles 25. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool from the steering column harness side of the driver air bag module electrical connector. 26. Connect the driver air bag module electrical connector. 27. Install the driver air bag connector access cover. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Driver Seat > Page 7619 28. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Remove the special tool to the instrument panel harness side of the passenger air bag module electrical connector. 29. Connect the passenger air bag module electrical connector. 30. Raise the glove compartment. - Press the locking tabs. 31. Connect the battery ground cable. 32. Prove out the air bag system. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 7620 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations View 151-15 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7626 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Master Window/Door Lock/Unlock Switch View 151-34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Master Window/Door Lock/Unlock Switch > Page 7631 View 151-33 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 7634 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7637 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7638 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7639 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7643 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7644 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7645 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7646 Exterior Rear View Mirror Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations View 151-24 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7650 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7651 Power Seat Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7652 Power Seat Switch: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7653 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7654 Power Seat Switch: Service and Repair SEAT CONTROL SWITCH REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic toot must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Disconnect the battery ground cable. 2. Remove the seat control switch knob. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 7655 3. Remove the front seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - Disconnect the electrical connector(s). 4. Remove the seat control switch 1 Remove the screws. 2 Remove the switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Side Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Side > Page 7660 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7661 Seat Heater Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7662 Seat Heater Switch: Service and Repair HEATED SEAT SWITCH REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. Failure to follow these instructions may result in personal injury. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterward. Failure to follow these instructions may result in personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which may result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate component or system to determine location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove may result in personal injury and possible violation of vehicle safety standards. NOTE: - Diagnostics or repairs are not to be carried out on a side air bag system or a safety belt pretensioner (if equipped) with the seat in the vehicle. Prior to attempting to diagnose/repair the side air bag system or a safety belt pretensioner (if equipped) the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side air bag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be carried out on seat systems other than the side air bag system or a safety belt pretensioner (if equipped) (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side air bag to floor connector. - A repair is made by installing a new part only. If a new part is installed and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - If a side air bag deployment took place, a new seatback pad, trim cover, and side air bag module must be installed. A new seatback frame should be installed if necessary. 1. Disconnect the battery ground cable. 2. Remove the seat control switch knob. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7663 3. Remove the front seat cushion side shield. 1 Remove the seat backrest handle. 2 Remove the screw. 3 Remove the shield. - Disconnect the electrical connectors. 4. Release the locking tab and remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Roof Opening Panel Switch > Page 7668 View 151-21 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Roof Opening Panel Position Switch > Page 7671 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is made of urethane, PVC, and recycled felt. Insulation is installed: - under the roof panel. - above and below the instrument panel - on the cowl sides. - over the front and rear floor areas. - in the A, B. and D-pillar sections. - behind the rear quarter trim panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the wiper pivot arms. 1 Remove the nuts. 2 Remove the wiper pivot arm. 2. Remove the driver side cowl grille. 1 Remove the pin-type retainers. 2 Remove the screw caps and screws. 3 Remove the cowl grille. 3. Remove the passenger side cowl grille. 1 Remove the pin-type retainers. 2 Remove the screw caps and screws. 3 Remove the cowl grille. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 7685 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 7688 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 7689 Brake Switch (Cruise Control): Service Precautions CAUTION: Initial installation of a deactivator switch allows for one adjustment. If additional adjustments are required, install a new switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 7690 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Remove the deactivator switch. 1 Disconnect the electrical connector. 2 Rotate counterclockwise 45 degrees and remove the deactivator switch. INSTALLATION CAUTION: Initial installation of a deactivator switch allows for one adjustment. If additional adjustments are required, install a new switch. 1. Release the plunger lock. ^ Turn the lock knob counterclockwise until the first click is felt. 2. Depress the brake pedal. 3. Install the deactivator switch. 1 Position the deactivator switch in the bracket and rotate clockwise 45 degrees. 2 Connect the electrical connector. 4. Slowly release the brake pedal and tug moderately once the pedal reaches the rest position. NOTE: There should be an extra click heard when tugging on the brake pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 7694 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Release the speed control cable cap. 1 Squeeze the speed control cable cap retaining tab. 2 Rotate the speed control cable cap. 3. Remove the speed control cable. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and remove the speed control cable. 4. Remove the speed control actuator assembly. 1 Disconnect the electrical connector. 2 Separate the wire harness from the bracket. 3 Remove the nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 7695 5. Remove the bolts and separate the speed control actuator from the bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect the speed control cable from the throttle control linkage and bracket. 2. Release the speed control cable cap. 1 Depress the speed control cable cap retaining tab. 2 Rotate the speed control cable cap. 3. Remove the speed control cable. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and remove the speed control cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service Precautions Cruise Control Switch: Service Precautions WARNING: WHEN CARRYING A LIVE AIR BAG, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOUR BODY. IN THE UNLIKELY EVENT OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 7702 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the steering wheel cover. WARNING: WHEN CARRYING A LIVE AIR BAG, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOUR BODY. IN THE UNLIKELY EVENT OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Remove the steering wheel frame. 1 Remove the nuts. 2 Disconnect the ground wire. 3 Remove the steering wheel frame. 4. Disconnect the speed control switches electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 7703 5. Remove the speed control switches. 1 Remove the screws. 2 Remove the speed control switches. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 7709 View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 7712 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 7713 Brake Switch (Cruise Control): Service Precautions CAUTION: Initial installation of a deactivator switch allows for one adjustment. If additional adjustments are required, install a new switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 7714 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Remove the deactivator switch. 1 Disconnect the electrical connector. 2 Rotate counterclockwise 45 degrees and remove the deactivator switch. INSTALLATION CAUTION: Initial installation of a deactivator switch allows for one adjustment. If additional adjustments are required, install a new switch. 1. Release the plunger lock. ^ Turn the lock knob counterclockwise until the first click is felt. 2. Depress the brake pedal. 3. Install the deactivator switch. 1 Position the deactivator switch in the bracket and rotate clockwise 45 degrees. 2 Connect the electrical connector. 4. Slowly release the brake pedal and tug moderately once the pedal reaches the rest position. NOTE: There should be an extra click heard when tugging on the brake pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions Cruise Control Switch: Service Precautions WARNING: WHEN CARRYING A LIVE AIR BAG, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOUR BODY. IN THE UNLIKELY EVENT OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 7718 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the steering wheel cover. WARNING: WHEN CARRYING A LIVE AIR BAG, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOUR BODY. IN THE UNLIKELY EVENT OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Remove the steering wheel frame. 1 Remove the nuts. 2 Disconnect the ground wire. 3 Remove the steering wheel frame. 4. Disconnect the speed control switches electrical connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 7719 5. Remove the speed control switches. 1 Remove the screws. 2 Remove the speed control switches. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 Audible Warning Device: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 Audible Warning Device: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 66-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 66-2 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 Cigarette Lighter: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 44-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 44-2 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7778 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7779 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7780 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7781 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7782 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7783 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Page 7787 Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Page 7788 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Page 7789 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH REMOVAL 1. Remove the instrument panel dimmer switch. 2. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Ajar Switch View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 7794 View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 7797 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Procedure Depowering Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F2.5 (5A) and F2.7 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuses F2.5 (5A) and F2.7 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7804 Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Access the driver air bag module electrical connector to the clockspring behind the access panel on the bottom of the steering wheel. 4. Disconnect the driver air bag module electrical connector. 5. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 6. Disconnect the passenger air bag. 7. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 8. If equipped with side air bags, remove the affected front seat. 9. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F470 to the passenger side air bag floor electrical connector. 10. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 11. Disconnect (if necessary) attach a restraint system diagnostic tool 418-F470 to the driver side floor electrical connector. 12. Disconnect (if necessary) and attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7805 There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Access the driver air bag module electrical connector to the clockspring behind the access panel in the bottom of the steering wheel. 5. Disconnect the driver air bag module electrical connector to the clockspring. 6. Attach a restraint system diagnostic tool 418-F468 to the clockspring side of the driver air bag module electrical connector. 7. Disconnect the passenger air bag module electrical connector. 8. Attach a restraint system diagnostic tool 418-F468 to the harness side of the passenger air bag module electrical connector. 9. If equipped with side air bags, disconnect the passenger side air bag module electrical connector beneath the front seat. 10. Attach a restraint system diagnostic tool 418-F470 to the passenger side air bag electrical connector beneath the passenger seat. 11. Attach a restraint system diagnostic tool 418-F468 to the passenger safety belt buckle electrical connector. 12. If equipped with side air bags, disconnect the driver side air bag module electrical connector beneath the driver seat. 13. Attach a restraint system diagnostic tool 418-F470 to the driver side air bag module electrical connector beneath the front seat. 14. Attach a restraint system diagnostic tool 418-F468 to the driver safety belt buckle electrical connector. 15. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7806 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Install the affected front seat. 8. Connect the drive and passenger seat belt buckle pretensioner electrical connectors. 9. If equipped with side air bags, connect the driver and passenger side air bag module electrical connectors. 10. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 11. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Reconnect the passenger air bag module electrical connector. 13. Reconnect the battery ground cable. 14. Prove out the system. See: Prove Out Procedure Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. 1. Disconnect the battery ground cable. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the restraint system diagnostic tool from the clockspring connector. ^ Reconnect the electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7807 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. If equipped with side air bags, remove the restraint system diagnostic tool from the driver side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. If equipped with side air bags, connect the driver side air bag module electrical connector. 6. Remove the restraint system diagnostic tool from the driver seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 7. Remove the restraint system diagnostic tool from the passenger side air bag electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. If equipped with side air bags, connect the passenger side air bag module electrical connector. 9. Remove the restraint system diagnostic tool from the passenger seat belt buckle pretensioner electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Reconnect the battery ground cable. 11. Prove out the system. See: Prove Out Procedure Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7808 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. All in-seat electrical connectors connected? 2. All air bag modules connected? 3. Restraints Control Module (RCM) connected? 4. All safety belt pretensioners connectors connected? 5. All sensors (side impact) connected? 6. Battery connected? Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7809 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb INSTRUMENT CLUSTER BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the instrument cluster bulbs. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 7814 Instrument Panel Bulb: Service and Repair Warning Indicator Bulb WARNING INDICATOR BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the desired miniature bulb by turning it a quarter turn counterclockwise and lifting straight up. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Relay > Component Information > Testing and Inspection Instrument Panel Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Relay > Component Information > Testing and Inspection > Page 7818 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) (Figure 17) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 18). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Malfunction Indicator Lamp (MIL) CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sender ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 7828 View 151-6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 7829 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 7830 Oil Pressure Sender: Service and Repair Oil Pressure Sender Removal and Installation 1. Raise and support the vehicle. 2. NOTE: The halfshaft is removed for clarity. Disconnect the oil pressure sender electrical connector. 3. Remove the oil pressure sender. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7837 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7838 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake warning indicator switch. ^ Remove the screws. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Testing and Inspection Instrument Panel Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Relay > Component Information > Testing and Inspection > Page 7843 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning System The safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten their safety belts. The conditions of operation for the safety belt warning indicator and chime are as follows: ^ If the driver's safety belt is not buckled before the ignition switch is turned to RUN, the safety belt warning indicator illuminates for 1-2 minutes and the warning chime sounds for 4-8 seconds. ^ If the driver's safety belt is buckled while the warning indicator is illuminated and the reminder chime is sounding, the safety belt warning indicator and reminder chime turn off. ^ If the driver's safety belt is buckled before the ignition switch is turned to RUN, the safety belt warning indicator and reminder chime remain off. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning System The safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten their safety belts. The conditions of operation for the safety belt warning indicator and chime are as follows: ^ If the driver's safety belt is not buckled before the ignition switch is turned to RUN, the safety belt warning indicator illuminates for 1-2 minutes and the warning chime sounds for 4-8 seconds. ^ If the driver's safety belt is buckled while the warning indicator is illuminated and the reminder chime is sounding, the safety belt warning indicator and reminder chime turn off. ^ If the driver's safety belt is buckled before the ignition switch is turned to RUN, the safety belt warning indicator and reminder chime remain off. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 7854 Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 7855 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 7856 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH REMOVAL 1. Remove the instrument panel dimmer switch. 2. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Ajar Switch View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 7861 View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 7864 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-26 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7868 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7869 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake warning indicator switch. ^ Remove the screws. 3. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair Shift Indicator: Service and Repair SELECTOR LEVER INDICATOR BULB REMOVAL 1. Remove the instrument cluster. 2. Remove the selector lever indicator bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Transmission Range Sensor View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Transmission Range Sensor > Page 7879 View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Transmission Range (TR) Sensor Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Transmission Range (TR) Sensor > Page 7882 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 7891 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 7897 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Brake Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 Brake Lamp: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 Brake Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 90-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 90-2 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the stoplamps. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage. 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 fault is not visually evident, verify the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7924 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7925 Brake Lamp: Pinpoint Tests Test J PINPOINT TEST J: THE STOPLAMPS ARE INOPERATIVE Test J1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7926 Test J2-J3 Test K PINPOINT TEST K: ONE OR MORE STOPLAMPS ARE INOPERATIVE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7927 Test K1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7928 Test K2 Test L PINPOINT TEST L: THE STOPLAMPS ARE ON CONTINUOUSLY Test L1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 7929 73III Automotive Meter Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7933 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7934 Brake Light Switch: Service and Repair BRAKE PEDAL POSITION (BPP) SWITCH REMOVAL 1. Remove the brake pedal position (BPP) switch. 1 Disconnect the electrical connector. 2 Rotate clockwise and remove the BPP switch. INSTALLATION NOTE: Initial installation of brake pedal position (BPP) switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. To unlock, rotate the lock knob counterclockwise to the stop. 2. With the engine running, fully depress and hold the brake pedal. 3. Install the brake pedal position (BPP) switch. 1 Position the BPP switch in the bracket and rotate counterclockwise. 2 Connect the electrical connector. 4. Slowly release the brake pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Cargo Lamp: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 7938 Cargo Lamp: Service and Repair CARGO LAMP REMOVAL 1. Disconnect the battery ground cable. 2. Remove the cargo lamp assembly from the headliner. 3. Remove the cargo lamp assembly. 1 Disconnect the electrical connectors. 2 Remove the cargo lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair HIGH MOUNTED STOPLAMP BULB REMOVAL 1. Remove the high-mounted stoplamp assembly. - Remove and discard the screws and washers. 2. Remove the high-mounted stoplamp bulb holder from the lamp assembly by disengaging the snaps. 3. Remove the bulb(s). INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 Courtesy Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Courtesy Lamp: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 Courtesy Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 89-1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 89-2 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 7969 Courtesy Lamp: Description and Operation PRINCIPLES OF OPERATION Interior Lighting The generic electronic module (GEM) supplies voltage and ground to the interior courtesy lamps when any of the following inputs are received: any door becomes ajar - liftgate or liftgate glass becomes ajar - remote keyless entry unlock signal is received - a key cylinder switch is turned to UNLOCK All interior courtesy lamps are turned off when any of the following occurs: all the doors, liftgate and liftgate glass are closed - the ignition switch is turned to RUN - a key cylinder switch is turned to LOCK - remote keyless entry lock signal is received The illuminated entry feature is another feature which activates the interior lamps. This feature operates as follows: The GEM illuminates the interior lamps at 80 percent brightness when an unlock signal is received from a remote keyless entry transmitter, key cylinder switch, or door handle lifted when locked. If no door ajar signal is received the GEM will time out and turn the interior lights off. The illuminated entry feature will be canceled when any of the following conditions are met: the remote transmitter lock button is pressed and the courtesy lamp control is not activated. - the ignition is in the RUN or START position and the interior lamp control is not activated. Battery Saver The GEM is equipped with a battery saver which will turn the lights off after 45 minutes of inactivity. This feature is an internal function of the GEM software. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Courtesy Lamp: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the system. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If an obvious cause for an observed of reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the diagnostic tool does not power up, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: - CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). - NO RESP/NOT EQUIP for GEM, Refer to Multifunction Electronic Control Module (General Module). - SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures 8. If the DTCs are retrieved that are not found in the GEM Diagnostic Trouble Code (DTC) Index, refer to the master GEM Diagnostic Trouble Code (DTC) Index in Multifunction Electronic Control Module (General Module). See: Accessories and Optional Equipment/General Module/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7972 DTC Index B1317 - B1571 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7973 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7974 Courtesy Lamp: Pinpoint Tests Test A PINPOINT TEST A: THE INTERIOR LAMPS ARE INOPERATIVE Test A1-A2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7975 Test A3-A4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7976 Test A5-A6 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7977 Test A6-A8 Test B PINPOINT TEST B: THE INTERIOR LAMPS STAY ON CONTINUOUSLY - DO NOT FADE OUT Test B1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7978 Test B2-B4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7979 Test B5-B7 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7980 Test B8-B10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7981 Test B11-B13 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7982 Test B14-B16 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7983 Test B17-B19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7984 Test B20-B22 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7985 Test B23-B25 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7986 Test B26-B28 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7987 Test B29-B31 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7988 Test B32-B34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7989 Test B35-B36 Test C PINPOINT TEST C: THE INTERIOR LAMPS DO NOT TURN ON WITH ONE DOOR OPEN Test C1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7990 Test C1-C3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7991 Test C4 Test D PINPOINT TEST D: THE ILLUMINATED ENTRY IS INOPERATIVE WHEN USING THE REMOTE TRANSMITTER Test D1-D2 Test E PINPOINT TEST E: THE DEMAND LIGHTING IS INOPERATIVE Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7992 Test E1-E2 Test E2-E4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7993 Test F PINPOINT TEST F: BATTERY VOLTAGE OUT OF RANGE Test F1 Test F2-F3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 7994 Courtesy Lamp: Service and Repair INTERIOR/MAP READING LAMP REMOVAL 1. Disconnect the battery ground cable. 2. Remove the interior/map reading lamp lens. 3. Remove the interior/map reading lamp assembly. 1 Remove the screws. 2 Remove the interior/map reading lamp. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 7995 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8000 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8001 Daytime Running Lamp Control Unit: Service and Repair DAYTIME RUNNING LAMPS (DRL) MODULE REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and the DRL module. - Disconnect the electrical connectors. - Transfer parts as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 8005 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay Daytime Running Lamp Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8008 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8009 Daytime Running Lamp Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8010 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Page 8014 Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Page 8015 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Page 8016 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH REMOVAL 1. Remove the instrument panel dimmer switch. 2. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 8021 View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 8024 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Technician Safety Information Fog/Driving Lamp Bulb: Technician Safety Information WARNING: The halogen fog lamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 8030 Fog/Driving Lamp Bulb: Vehicle Damage Warnings CAUTION: The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Page 8031 Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB REMOVAL WARNING: The halogen fog lamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. CAUTION: The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. 1. Remove the wheel and tire. 2. Position the inner fender well aside. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the screw. 4 Position the inner fender well aside. 3. Remove the lamp socket from the lamp assembly. - Disconnect the electrical connector. 4. Disconnect the bulb from the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8035 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8036 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8037 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 8041 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 8042 Fog/Driving Lamp Switch: Service Precautions CAUTION: Do not use a screwdriver to remove fog lamp switch or damage to the finish panel may occur. Adding tape to the end of a thin tool will reduce marring to the finish panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 8043 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REMOVAL 1. Disconnect the battery ground cable. CAUTION: Do not use a screwdriver to remove fog lamp switch or damage to the finish panel may occur. Adding tape to the end of a thin tool will reduce marring to the finish panel. 2. Use a thin tool to remove the fog lamp switch. 3. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 8048 Hazard Warning Flasher: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 8049 Hazard Warning Flasher: Application and ID The flasher function for this vehicle is provided by Electronic Flasher Module and Generic Electronic Module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8053 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8054 Hazard Warning Switch: Service and Repair Hazard Flasher Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Position the instrument panel center finish panel removal from the instrument panel. 3. Remove the hazard flasher switch. 1 Disconnect electrical connector. 2 Remove the hazard flasher switch. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information Headlamp Bulb: Technician Safety Information WARNING: The halogen headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 8060 Headlamp Bulb: Vehicle Damage Warnings CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 8061 Headlamp Bulb: Service and Repair HEADLAMP BULB REMOVAL WARNING: The halogen headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed. 1. NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. Disconnect the headlamp electrical connector. 2. Remove the rubber boot. 3. Depress the retainer clip and position aside. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 8062 4. Remove the bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Application and ID Headlamp Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8069 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8070 Headlamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 8071 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations View 151-20 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8075 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8076 Headlamp Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8077 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8082 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8083 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8084 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Application and ID Interior Lighting Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8098 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8102 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8103 License Plate Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8105 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 License Plate Lamp: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 License Plate Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 8114 License Plate Lamp: Service and Repair LICENSE PLATE LAMP REMOVAL 1. Remove the license plate lamp assembly. - Push the license lamp to the right and pull out. 2. Disconnect the socket from the lens. - Remove the bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Service and Repair Map Light: Service and Repair INTERIOR/MAP READING LAMP REMOVAL 1. Disconnect the battery ground cable. 2. Remove the interior/map reading lamp lens. 3. Remove the interior/map reading lamp assembly. 1 Remove the screws. 2 Remove the interior/map reading lamp. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Marker Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 Marker Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8143 Marker Lamp: Service and Repair SIDE LAMP/FRONT TURN SIGNAL LAMP BULB REMOVAL 1. Remove the wheel and tire. 2. Position the inner fender well aside. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the screw. 4 Position the inner fender well aside. 3. Remove the lamp socket from the lamp assembly. 4. Remove the bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8148 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8149 Parking Lamp Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8150 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8155 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 8156 Daytime Running Lamp Control Unit: Service and Repair DAYTIME RUNNING LAMPS (DRL) MODULE REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and the DRL module. - Disconnect the electrical connectors. - Transfer parts as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 8160 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay Daytime Running Lamp Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8163 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8164 Daytime Running Lamp Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8165 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8169 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8170 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8171 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Application and ID Headlamp Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8178 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8179 Headlamp Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 8180 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8184 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8185 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8186 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Application and ID Interior Lighting Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8193 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8194 Parking Lamp Relay: Testing and Inspection Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8195 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Transmission Range Sensor View 151-9 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Transmission Range Sensor > Page 8201 View 151-10 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range (TR) Sensor Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Transmission Range (TR) Sensor > Page 8204 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-23 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8208 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8209 Brake Light Switch: Service and Repair BRAKE PEDAL POSITION (BPP) SWITCH REMOVAL 1. Remove the brake pedal position (BPP) switch. 1 Disconnect the electrical connector. 2 Rotate clockwise and remove the BPP switch. INSTALLATION NOTE: Initial installation of brake pedal position (BPP) switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. To unlock, rotate the lock knob counterclockwise to the stop. 2. With the engine running, fully depress and hold the brake pedal. 3. Install the brake pedal position (BPP) switch. 1 Position the BPP switch in the bracket and rotate counterclockwise. 2 Connect the electrical connector. 4. Slowly release the brake pedal. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 8214 View 151-32 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 8217 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 8221 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 8222 Fog/Driving Lamp Switch: Service Precautions CAUTION: Do not use a screwdriver to remove fog lamp switch or damage to the finish panel may occur. Adding tape to the end of a thin tool will reduce marring to the finish panel. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 8223 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REMOVAL 1. Disconnect the battery ground cable. CAUTION: Do not use a screwdriver to remove fog lamp switch or damage to the finish panel may occur. Adding tape to the end of a thin tool will reduce marring to the finish panel. 2. Use a thin tool to remove the fog lamp switch. 3. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations View 151-18 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8227 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8228 Hazard Warning Switch: Service and Repair Hazard Flasher Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Position the instrument panel center finish panel removal from the instrument panel. 3. Remove the hazard flasher switch. 1 Disconnect electrical connector. 2 Remove the hazard flasher switch. 4. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-20 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8232 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8233 Headlamp Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8234 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8239 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8240 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8241 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8248 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8249 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8250 Tail Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8251 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8252 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8253 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8254 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8255 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8256 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8257 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8258 Tail Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8259 See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 8260 Tail Lamp: Service and Repair REAR LAMP ASSEMBLY REMOVAL 1. Remove the rear lamp assembly. 1 Remove the bolts. 2 Pull straight back to remove the rear lamp assembly. - Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How To Navigate Between Wiring Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8265 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Introduction To Ford Diagrams Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8266 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8267 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8268 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8269 Power and Ground Distribution Diagrams contain the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8270 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8271 Symbols Part 2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8272 Symbols Part 3 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8273 Symbols Part 4 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8274 Symbols Part 5 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8275 Systems Overview Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8276 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation in each illustration. NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 Locked terminal 2 Male half 3 Female half 4 Seal 5 Intermittent contact 6 Unlocked terminal (Hidden by wire seal) 7 Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8277 Defective insulation stripping 1 Proper crimp 2 Insulation not removed 3 Wire strands missing 4 Intermittent signals through pierced insulation Partially mated connectors 1 Seal 2 Displaced tab 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8278 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 Enlarged 2 Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 Solder coated wire to ground 2 Harness protective tape 3 Intermittent short Solder coated wire pierced through the insulation of another circuit 4 Grounding foil Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8279 Electrical short within the harness Splice tape removed 1 Intermittent short Splice covered 1 Wire strand Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8280 2 Splice tape 3 Harness tape Broken wire strands in harness 1 Wiring harness tape 2 Wiring strand 3 Broken strands intermittent signal 4 Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8281 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 6. Bend Wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8284 Trailer Lamps: Electrical Diagrams Trailer/Camper Adapter PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations -- Location views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse: 21 (10A) - 16 (10A) - Connections - Circuitry - Relays - Bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8287 Symptom Chart Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8288 Trailer Lamps: Pinpoint Tests Tests AB PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE Test AB1 Tests AC PINPOINT TEST AC: THE TRAILER LAMPS ARE INOPERATIVE - BOTH TRAILER TURN SIGNALS/STOPLAMPS/HAZARD LAMPS Test AC1-AC2 Tests AD PINPOINT TEST AD: THE INDIVIDUAL TRAILER LAMPS IS INOPERATIVE - RH TRAILER TURN SIGNALS/STOPLAMPS/HAZARD Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8289 LAMPS Test AD1 Tests AE PINPOINT TEST AE: THE INDIVIDUAL TRAILER LAMPS IS INOPERATIVE-LH TRAILER TURN SIGNALS/STOPLAMPS/HAZARD LAMPS Test AE1 Tests AF PINPOINT TEST AF: THE INDIVIDUAL TRAILER LAMPS IS INOPERATIVE-PARKING LAMPS Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8290 Test AF1-AF2 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 8291 73III Automotive Meter Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations View 151-17 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 8296 Turn Signal Flasher: Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 8297 Turn Signal Flasher: Application and ID The flasher function for this vehicle is provided by Electronic Flasher Module and Generic Electronic Module. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair SIDE LAMP/FRONT TURN SIGNAL LAMP BULB REMOVAL 1. Remove the wheel and tire. 2. Position the inner fender well aside. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the screw. 4 Position the inner fender well aside. 3. Remove the lamp socket from the lamp assembly. 4. Remove the bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left > Page 8306 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8312 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay Heated Glass Element Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8315 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8316 Heated Glass Element Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8317 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations View 151-19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 8321 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 8322 Heated Glass Element Switch: Service and Repair REAR WINDOW DEFROST SWITCH REMOVAL 1. Remove the audio unit. 2. Push outward on the rear window defrost switch to remove it from the instrument panel center finish panel. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8327 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8328 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8329 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8330 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 8331 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8336 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay Heated Glass Element Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8339 Relay - Mini ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8340 Heated Glass Element Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Mini ISO Relay > Page 8341 Relay - Micro ISO Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations View 151-19 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 8346 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 8347 Heated Glass Element Switch: Service and Repair REAR WINDOW DEFROST SWITCH REMOVAL 1. Remove the audio unit. 2. Push outward on the rear window defrost switch to remove it from the instrument panel center finish panel. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side View 151-33 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side > Page 8352 View 151-35 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side > Page 8353 View 151-34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8356 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8357 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8358 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8361 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8362 Master Window Control Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8363 Power Window Switch: Testing and Inspection Window Adjust Switch Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8364 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 8365 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH NOTE: The removal and installation procedures for all window control switches are similar. REMOVAL 1. Remove the front door trim panel or the rear door trim panel. 2. Release the locking clips and remove the window control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 8372 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 8373 Front Door Window Motor: Service and Repair FRONT DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. 5. Connect the battery. All vehicles 6. Lower the front door window glass to gain access to the screws. Vehicles with power windows 7. Disconnect the battery. 8. Disconnect the window control switch electrical connector. 9. Remove the front door window glass screws. 10. Support the front door window glass in the full up position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 8374 11. Disconnect the front door power window regulator motor electrical connector. 12. Remove the front door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 13. Remove the front door window regulator assembly. 1 Remove the bolts 2 Remove the nuts. INSTALLATION All vehicles 1. To install, reverse the removal procedure. Cycle the door window glass to make sure of correct door window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left > Page 8379 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Page 8380 Rear Door Window Motor: Service and Repair REAR DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. All vehicles 5. Lower the rear door window glass to gain access to the screws. Vehicles with power windows 6. Disconnect the window control switch electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Page 8381 7. Remove the rear door window glass screws. 8. Support the rear door window glass in the full up position. Vehicles with power windows 9. Disconnect the rear door power window regulator electrical connector. 10. Remove the rear door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 11. Remove the rear door window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Page 8382 INSTALLATION All Vehicles 1. To install, reverse the removal procedure. Cycle the door glass to make sure of correct window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side View 151-33 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side > Page 8387 View 151-35 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Window Adjust Switch, Passenger Side > Page 8388 View 151-34 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8391 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8392 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window/Door Lock/Unlock Switch > Page 8393 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8396 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8397 Master Window Control Switch Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8398 Power Window Switch: Testing and Inspection Window Adjust Switch Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 8399 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 8400 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH NOTE: The removal and installation procedures for all window control switches are similar. REMOVAL 1. Remove the front door trim panel or the rear door trim panel. 2. Release the locking clips and remove the window control switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run Window Frame: Service and Repair Front Door Glass Top Run FRONT DOOR GLASS TOP RUN REMOVAL 1. Remove the front door window glass. 2. Remove the front door interior sail panel. - If equipped, disconnect the speaker electrical connector. 3. Remove the door glass top run bolts. 4. Remove the door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run > Page 8405 Window Frame: Service and Repair Rear Door Glass Top Run REAR DOOR GLASS TOP RUN REMOVAL 1. Remove the rear door window regulator. 2. Position the rear door window glass to the full down position. 3. Remove the screws and the rear door exterior sail panel. 4. Remove the rear door interior glass weatherstrip. 5. Remove the rear door exterior belt line moulding. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run > Page 8406 6. Remove the rear door glass top run bolts. 7. Position the rear door window glass down and forward. 8. Remove the rear door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair FRONT DOOR WINDOW GLASS REMOVAL 1. Remove the front door trim panel. 2. Remove the screw and the door trim panel bracket. 3. Position the water shield aside. 4. Remove the front door interior glass weatherstrip. 5. Connect the window control switch to the door harness. 6. Connect the battery. 7. Lower the front door window glass to gain access to the screws. 8. Remove the front door window glass screws. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 8411 9. Remove the front door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS REMOVAL 1. Open the liftgate glass. 2. Remove the two liftgate nut access covers (one on each side). 3. Disconnect the rear window glass electrical harness connector. 4. Disconnect the heated window grid wire electrical connector. 5. NOTE: An assistant may be needed to carry out this step. Disconnect the two liftgate window glass cylinders. 1 Slide the spring retainer to the end of the socket. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 8415 2 Disconnect the socket from the ball stud. 6. NOTE: An assistant may be needed to carry out this step. Remove the two liftgate window glass hinge nuts. INSTALLATION 1. To install, reverse the removal procedure. - Transfer components as necessary. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair REAR QUARTER WINDOW GLASS Interior Auto Glass Cut-Out Knife Kit SPECIAL TOOL(S) REMOVAL WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury. 1. Remove the headliner. 2. NOTE: - Lubricate the urethane adhesive with water to aid the special tool when cutting. - Locating tabs need to be cut through in order to remove the rear quarter window glass. The new quarter window glass will be equipped with new locating tabs. Using the special tool, cut the urethane adhesive from the quarter window glass starting at the top center and working toward the bottom corners and remove the rear quarter window glass. 3. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as temperatures and humidity vary.) Inadequate curing of the urethane adhesive will adversely affect the strength of the urethane bond. 1. Dry fit the quarter window glass, making alignment marks with tape or non-staining grease pencil. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8419 2. CAUTION: Do not scratch the pinch weld area. Trim the remaining urethane adhesive on the pinch weld to within the specification. The existing urethane adhesive surface should be smooth and free of cuts and contamination. 3. CAUTION: Use caution when applying Urethane Metal Primer Essex U-413. Apply a light amount of primer. Too much primer will run and damage the painted surface. Use a wool applicator to apply Urethane Medal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry. 4. Clean the inside of the quarter glass surface with alcohol-free cleaner, making sure the ceramic coated area is clean. 5. NOTE: Wipe off the glass prep immediately after each application because it flash dries. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B280-C twice around the glass surface to urethaned. 6. Apply Glass Primer Essex U-402 meeting Ford specification WSB-M2G314-B to the same area that was prepped in the previous step. Allow five minutes to dry. 7. Cut the urethane adhesive applicator tip to specification. 8. NOTE: Use caution when applying urethane adhesive. Apply to the outside edges of locating tabs on the glass surface. Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B. Start at the bottom and work around to the sides of the quarter window glass. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8420 9. Install the quarter window glass, aligning it to the marks previously made. 10. After the quarter window glass is set, check for water leaks and add urethane adhesive where needed. 11. If necessary, remove excess urethane adhesive from the outside surface of the quarter window glass. 12. Install the headliner. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REAR DOOR WINDOW GLASS REMOVAL 1. Remove the rear door glass top run. 2. Remove the rear door window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair FRONT DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. 5. Connect the battery. All vehicles 6. Lower the front door window glass to gain access to the screws. Vehicles with power windows 7. Disconnect the battery. 8. Disconnect the window control switch electrical connector. 9. Remove the front door window glass screws. 10. Support the front door window glass in the full up position. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 8428 11. Disconnect the front door power window regulator motor electrical connector. 12. Remove the front door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 13. Remove the front door window regulator assembly. 1 Remove the bolts 2 Remove the nuts. INSTALLATION All vehicles 1. To install, reverse the removal procedure. Cycle the door window glass to make sure of correct door window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair REAR DOOR WINDOW REGULATOR REMOVAL All vehicles 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. Position the water shield aside. Vehicles with power windows 4. Connect the window control switch electrical connector. All vehicles 5. Lower the rear door window glass to gain access to the screws. Vehicles with power windows 6. Disconnect the window control switch electrical connector. All vehicles Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 8432 7. Remove the rear door window glass screws. 8. Support the rear door window glass in the full up position. Vehicles with power windows 9. Disconnect the rear door power window regulator electrical connector. 10. Remove the rear door power window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Vehicles with manual windows 11. Remove the rear door window regulator assembly. 1 Remove the bolts. 2 Remove the nuts. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 8433 INSTALLATION All Vehicles 1. To install, reverse the removal procedure. - Cycle the door glass to make sure of correct window glass engagement. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: To prevent glass splinters from entering eyes or cutting hands, wear safety glass and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 8438 Windshield: Vehicle Damage Warnings CAUTION: - After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (Refer to the Essex drive away chart for the cure times as temperatures and humidity vary.). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. - Do not scratch the pinch weld area. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8439 Windshield: Service and Repair WINDSHIELD GLASS SPECIAL TOOL(S) REMOVAL WARNING: To prevent glass splinters from entering eyes or cutting hands, wear safety glass and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury. 1. Open the four A-pillar passenger assist handle covers. 2. Remove the two A-pillar passenger assist handles. 1 Remove the four bolts. 2 Remove the two A-pillar passenger assist handles. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8440 3. Remove the two windshield side garnish mouldings. 4. Remove the overhead console. 1 Open the front console door. 2 Remove the screws. 3 Remove the overhead console. If equipped, disconnect electrical connector. 5. Remove the two sun visors and two clips. 1 Remove the six screws 2 Remove the sun visors and clips. 6. Remove the driver and passenger assist handles. 7. Remove the interior rear view mirror. 8. Lower the front portion of the headliner. 9. Remove the cowl grille. 10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8441 11. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners. 12. Using the special tool, distance the windshield glass from the body. 13. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass. 14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (Refer to the Essex drive away chart for the cure times as temperatures and humidity vary.). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. 1. Dry fit the windshield glass, making alignment marks with tape or non-staining grease pencil. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8442 2. CAUTION: Do not scratch the pinch weld area. Trim the remaining urethane adhesive on the pinch weld to within the specification. The existing urethane adhesive surface should be smooth and free of cuts and contamination. 3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry. 4. If reinstalling the original windshield glass, remove the excess urethane adhesive and the windshield moulding. 5. Clean the inside of the windshield glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean. 6. NOTE: Wipe off the glass prep immediately after each application because it flash dries. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M5B280-C twice around the glass surface to be urethaned. 7. If installing a new windshield, apply Glass Primer Essex U-402 meeting Ford specification WSB-M2G314-B to the same area that was prepped in the pervious step. Allow five minutes to dry. 8. Apply foam dam meeting Ford specification WSB-M3G137-A to the bottom of the windshield glass. 9. Cut the urethane adhesive applicator tip to specification. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8443 10. Apply a bead of Urethane Adhesive Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the sides and top of the windshield glass. 11. Apply a bead of Urethane Adhesive Essex 400-HV which meets Ford specification WSB-M2G316-B to the bottom of the windshield glass outside the foam dam. 12. Install the windshield glass aligning it to the marks previously made. 13. After the windshield glass is set, check for water leaks and add urethane adhesive where needed. 14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass. 15. Install the cowl grille. 16. Reposition the front portion of the headliner. 17. Install the overhead console. 1 Position the overhead console. If equipped, connect the electrical connector. 2 Install the screws. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8444 18. Install the two sun visors and two clips. 1 Position the sun visors and clips. 2 Install the six screws. 19. Install the interior rear view mirror. 20. Install the two windshield side garnish mouldings. 21. Install the two A-pillar passenger assist handles. 1 Position the two assist handles. 2 Install the four bolts. 3 Close the four assist handle covers. 22. Install the driver and passenger assist handles. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 8445 Special Tool(s) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 8455 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 8456 Windshield Washer Switch: Service and Repair WINDSHIELD WIPER/WASHER SWITCH REMOVAL AND INSTALLATION 1. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. Remove the steering column shroud. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-20 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8460 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8461 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8462 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8463 Wiper Switch: Service and Repair WINDSHIELD WIPER/WASHER SWITCH REMOVAL AND INSTALLATION 1. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. Remove the steering column shroud. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid > Component Information > Specifications > Capacity Specifications Washer Fluid: Capacity Specifications Windshield Washer Fluid Windshield Washer Fluid 2.7 qts (2.6L) Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid > Component Information > Specifications > Capacity Specifications > Page 8468 Washer Fluid: Fluid Type Specifications Windshield Washer Fluid Windshield Washer Fluid Type Motorcraft Premium Windshield Washer Fluid Concentrate Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair WASHER HOSE REPAIR 1. Locate and verify the leaking washer hose. 2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a windshield washer hose adapter between the cut ends of the hose. 4. NOTE: In difficult cases, clamping may be required. Install a segment of 6.4 mm (0.25 in) i.d. black rubber hose over the ends of the washer hose, and clamp both ends of the rubber hose using spring clamps. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Technician Safety Information Windshield Washer Pump: Technician Safety Information WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Technician Safety Information > Page 8480 Windshield Washer Pump: Vehicle Damage Warnings CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir to prevent component damage. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump Windshield Washer Pump: Service and Repair Windshield Washer Pump WINDSHIELD WASHER PUMP REMOVAL 1. Remove the RH front wheel and tire assembly. 2. Remove the RH front splash shield. 3. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Remove the windshield washer pump. 1 Disconnect the electrical connector. 2 Disconnect the hose. 3 Remove the windshield washer pump. INSTALLATION 1. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir to prevent component damage. Failure to follow these instructions may result in personal injury. To install, reverse the removal procedure. - WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump > Page 8483 Windshield Washer Pump: Service and Repair Rear Window Washer Pump REAR WINDOW WASHER PUMP REMOVAL 1. Remove the RH front wheel and tire assembly. 2. Remove the RH front splash shield. 3. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Remove the windshield washer pump. 1 Disconnect the electrical connector. 2 Disconnect the hose. 3 Remove the windshield washer pump. INSTALLATION 1. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. To install, reverse the removal procedure. - WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump > Page 8484 Windshield Washer Pump: Service and Repair Washer Pump and Reservoir WASHER PUMP AND RESERVOIR REMOVAL 1. Remove the right front wheel and tire assembly. 2. Remove the right front splash shield. 3. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. Position the windshield washer reservoir aside. 1 Remove the bolts. 2 Position the windshield washer reservoir aside. 4. Remove the windshield washer reservoir. 1 Disconnect the electrical connectors. 2 Disconnect the hoses. 3 Remove the windshield washer reservoir. INSTALLATION 1. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. To install, reverse the removal procedure. - WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Technician Safety Information Windshield Washer Reservoir: Technician Safety Information WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Technician Safety Information > Page 8489 Windshield Washer Reservoir: Vehicle Damage Warnings CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Page 8490 Windshield Washer Reservoir: Service and Repair WASHER PUMP AND RESERVOIR REMOVAL 1. Remove the right front wheel and tire assembly. 2. Remove the right front splash shield. 3. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. Position the windshield washer reservoir aside. 1 Remove the bolts. 2 Position the windshield washer reservoir aside. 4. Remove the windshield washer reservoir. 1 Disconnect the electrical connectors. 2 Disconnect the hoses. 3 Remove the windshield washer reservoir. INSTALLATION 1. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. To install, reverse the removal procedure. - WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 8494 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 8495 Windshield Washer Switch: Service and Repair WINDSHIELD WIPER/WASHER SWITCH REMOVAL AND INSTALLATION 1. NOTE: The windshield wiper/washer switch is part of the multifunction switch assembly. Remove the steering column shroud. 2. Remove the screws. 3. Remove the windshield wiper/washer switch. 1 Disconnect the electrical connector. 2 Remove the windshield wiper/washer switch. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Customer Interest for Wiper Arm: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor Wiper Arm: Customer Interest Wipers/Washers - Rear Wiper Arm Seized to Motor Article No. 03-20-1 10/13/03 ELECTRICAL - REAR WIPER ARM REMOVAL - SERVICE TIP FORD: 2001-2004 ESCAPE ISSUE Some Escape vehicles may exhibit the rear wiper arm being seized to the motor and difficult to remove. This may be caused by an insufficient amount of anti-seize compound on the arm/motor shaft splines. ACTION For vehicle service requiring the removal of the rear wiper arm, the following Service Procedure will help to free the wiper arm from the motor shaft. NOTE DO NOT ATTEMPT TO REMOVE THE WIPER ARM BY CUTTING THE MOTOR SHAFT WITH A HACKSAW OR GRIND TOOL. CUTTING THE MOTOR SHAFT WILL MAKE THE MOTOR UNUSABLE REQUIRING REPLACEMENT. IN ADDITION, DAMAGE TO THE LIFTGATE GLASS MAY OCCUR. HOWEVER IF THE REASON FOR SERVICE IS DUE TO AN INOPERABLE REAR WIPER MOTOR AND THE WIPER ARM IS SEIZED, THEN CUTTING THE MOTOR SHAFT IS AN ACCEPTABLE MEANS OF REMOVAL. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. SERVICE PROCEDURE 1. Confirm that wiper arm is seized on motor and that the wiper arm retainer latch is in the "release" position. 2. Mark and LIGHTLY center punch the exact center of arm mount "circle" (area over motor shaft). 3. Carefully drill through wiper arm using 1/8" drill bit. Do not drill into the motor shaft. NOTE PREVENT METAL SHAVINGS FROM FALLING ONTO THE BODY OR PAINT AS DAMAGE MAY OCCUR. 4. Enlarge the drilled hole using 3/8" drill bit. 5. Apply a small amount of penetrating oil at contact area of splines for wiper arm and motor. 6. Tap on joint area lightly to create vibration and facilitate penetrating oil working into splines of arm and motor. 7. Allow the oil to sit and penetrate for several minutes. NOTE BE SURE THE WIPER ARM RETAINER CLIP IS IN THE "RELEASE" POSITION BEFORE CONTINUING WITH STEP 8. 8. Install a puller with a 5/16" or smaller center screw (e.g. Battery Clamp Puller) to the wiper arm so that jaws of puller are pulling against the arm, and center post of puller is pressing against center of wiper motor shaft. NOTE ENSURE THAT JAWS OF PULLER ARE PULLING AGAINST WIPER ARM AND NOT MOTOR SHAFT BUSHING. 9. Tighten puller in very small increments while tapping lightly on the wiper arm and center shaft of puller. With pressure applied to the wiper arm and shaft a light shock should pop arm off of motor shaft. NOTE BE CAREFUL THAT ARM & PULLER DO NOT FALL AND DAMAGE THE LIFTGATE AND/OR BUMPER. 10. When installing the new wiper arm, remove all corrosion/rust from motor splines and apply anti-seize compound to splines of arm and motor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Customer Interest for Wiper Arm: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor > Page 8504 NOTE IF AFTER PERFORMING THIS PROCEDURE THE WIPER ARM STILL CANNOT BE REMOVED, THEN CAREFULLY CUT MOTOR SHAFT AND REPLACE MOTOR AND WIPER ARM. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Arm: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor Wiper Arm: All Technical Service Bulletins Wipers/Washers - Rear Wiper Arm Seized to Motor Article No. 03-20-1 10/13/03 ELECTRICAL - REAR WIPER ARM REMOVAL - SERVICE TIP FORD: 2001-2004 ESCAPE ISSUE Some Escape vehicles may exhibit the rear wiper arm being seized to the motor and difficult to remove. This may be caused by an insufficient amount of anti-seize compound on the arm/motor shaft splines. ACTION For vehicle service requiring the removal of the rear wiper arm, the following Service Procedure will help to free the wiper arm from the motor shaft. NOTE DO NOT ATTEMPT TO REMOVE THE WIPER ARM BY CUTTING THE MOTOR SHAFT WITH A HACKSAW OR GRIND TOOL. CUTTING THE MOTOR SHAFT WILL MAKE THE MOTOR UNUSABLE REQUIRING REPLACEMENT. IN ADDITION, DAMAGE TO THE LIFTGATE GLASS MAY OCCUR. HOWEVER IF THE REASON FOR SERVICE IS DUE TO AN INOPERABLE REAR WIPER MOTOR AND THE WIPER ARM IS SEIZED, THEN CUTTING THE MOTOR SHAFT IS AN ACCEPTABLE MEANS OF REMOVAL. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. SERVICE PROCEDURE 1. Confirm that wiper arm is seized on motor and that the wiper arm retainer latch is in the "release" position. 2. Mark and LIGHTLY center punch the exact center of arm mount "circle" (area over motor shaft). 3. Carefully drill through wiper arm using 1/8" drill bit. Do not drill into the motor shaft. NOTE PREVENT METAL SHAVINGS FROM FALLING ONTO THE BODY OR PAINT AS DAMAGE MAY OCCUR. 4. Enlarge the drilled hole using 3/8" drill bit. 5. Apply a small amount of penetrating oil at contact area of splines for wiper arm and motor. 6. Tap on joint area lightly to create vibration and facilitate penetrating oil working into splines of arm and motor. 7. Allow the oil to sit and penetrate for several minutes. NOTE BE SURE THE WIPER ARM RETAINER CLIP IS IN THE "RELEASE" POSITION BEFORE CONTINUING WITH STEP 8. 8. Install a puller with a 5/16" or smaller center screw (e.g. Battery Clamp Puller) to the wiper arm so that jaws of puller are pulling against the arm, and center post of puller is pressing against center of wiper motor shaft. NOTE ENSURE THAT JAWS OF PULLER ARE PULLING AGAINST WIPER ARM AND NOT MOTOR SHAFT BUSHING. 9. Tighten puller in very small increments while tapping lightly on the wiper arm and center shaft of puller. With pressure applied to the wiper arm and shaft a light shock should pop arm off of motor shaft. NOTE BE CAREFUL THAT ARM & PULLER DO NOT FALL AND DAMAGE THE LIFTGATE AND/OR BUMPER. 10. When installing the new wiper arm, remove all corrosion/rust from motor splines and apply anti-seize compound to splines of arm and motor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Arm: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor > Page 8510 NOTE IF AFTER PERFORMING THIS PROCEDURE THE WIPER ARM STILL CANNOT BE REMOVED, THEN CAREFULLY CUT MOTOR SHAFT AND REPLACE MOTOR AND WIPER ARM. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment Wiper Arm: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers. 2. Verify that the RH and LH wiper blades are located at the specified position. 3. If not within specification, remove the windshield wiper pivot arms and reposition to the correct locations. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment > Page 8513 Wiper Arm: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the rear window wiper. 2. Verify that the rear window wiper blade is located at the specified position. 3. If not within specification, remove the rear window wiper pivot arm and reposition to the correct location. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front Wiper Arm: Service and Repair Front WIPER PIVOT ARM - FRONT REMOVAL 1. Remove the pivot arm nut. 2. Remove the windshield wiper pivot arm. INSTALLATION 1. To install, reverse the removal procedure. - Adjust the windshield wiper pivot arms. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front > Page 8516 Wiper Arm: Service and Repair Rear WIPER PIVOT ARM - REAR REMOVAL 1. Remove the pivot arm. 1 Lift pivot arm to the upright position. 2 Slide the locking tab out. 3 Pull up and remove the pivot arm. INSTALLATION 1. To install, reverse the removal procedure. - Adjust the windshield wiper pivot arm. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment Wiper Blade: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers. 2. Verify that the RH and LH wiper blades are located at the specified position. 3. If not within specification, remove the windshield wiper pivot arms and reposition to the correct locations. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment > Page 8521 Wiper Blade: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the rear window wiper. 2. Verify that the rear window wiper blade is located at the specified position. 3. If not within specification, remove the rear window wiper pivot arm and reposition to the correct location. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information regarding this component please refer to Body Control Module / Generic Electronic Module (GEM). Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor Wiper Motor: Customer Interest Wipers/Washers - Rear Wiper Arm Seized to Motor Article No. 03-20-1 10/13/03 ELECTRICAL - REAR WIPER ARM REMOVAL - SERVICE TIP FORD: 2001-2004 ESCAPE ISSUE Some Escape vehicles may exhibit the rear wiper arm being seized to the motor and difficult to remove. This may be caused by an insufficient amount of anti-seize compound on the arm/motor shaft splines. ACTION For vehicle service requiring the removal of the rear wiper arm, the following Service Procedure will help to free the wiper arm from the motor shaft. NOTE DO NOT ATTEMPT TO REMOVE THE WIPER ARM BY CUTTING THE MOTOR SHAFT WITH A HACKSAW OR GRIND TOOL. CUTTING THE MOTOR SHAFT WILL MAKE THE MOTOR UNUSABLE REQUIRING REPLACEMENT. IN ADDITION, DAMAGE TO THE LIFTGATE GLASS MAY OCCUR. HOWEVER IF THE REASON FOR SERVICE IS DUE TO AN INOPERABLE REAR WIPER MOTOR AND THE WIPER ARM IS SEIZED, THEN CUTTING THE MOTOR SHAFT IS AN ACCEPTABLE MEANS OF REMOVAL. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. SERVICE PROCEDURE 1. Confirm that wiper arm is seized on motor and that the wiper arm retainer latch is in the "release" position. 2. Mark and LIGHTLY center punch the exact center of arm mount "circle" (area over motor shaft). 3. Carefully drill through wiper arm using 1/8" drill bit. Do not drill into the motor shaft. NOTE PREVENT METAL SHAVINGS FROM FALLING ONTO THE BODY OR PAINT AS DAMAGE MAY OCCUR. 4. Enlarge the drilled hole using 3/8" drill bit. 5. Apply a small amount of penetrating oil at contact area of splines for wiper arm and motor. 6. Tap on joint area lightly to create vibration and facilitate penetrating oil working into splines of arm and motor. 7. Allow the oil to sit and penetrate for several minutes. NOTE BE SURE THE WIPER ARM RETAINER CLIP IS IN THE "RELEASE" POSITION BEFORE CONTINUING WITH STEP 8. 8. Install a puller with a 5/16" or smaller center screw (e.g. Battery Clamp Puller) to the wiper arm so that jaws of puller are pulling against the arm, and center post of puller is pressing against center of wiper motor shaft. NOTE ENSURE THAT JAWS OF PULLER ARE PULLING AGAINST WIPER ARM AND NOT MOTOR SHAFT BUSHING. 9. Tighten puller in very small increments while tapping lightly on the wiper arm and center shaft of puller. With pressure applied to the wiper arm and shaft a light shock should pop arm off of motor shaft. NOTE BE CAREFUL THAT ARM & PULLER DO NOT FALL AND DAMAGE THE LIFTGATE AND/OR BUMPER. 10. When installing the new wiper arm, remove all corrosion/rust from motor splines and apply anti-seize compound to splines of arm and motor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor > Page 8533 NOTE IF AFTER PERFORMING THIS PROCEDURE THE WIPER ARM STILL CANNOT BE REMOVED, THEN CAREFULLY CUT MOTOR SHAFT AND REPLACE MOTOR AND WIPER ARM. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor Wiper Motor: All Technical Service Bulletins Wipers/Washers - Rear Wiper Arm Seized to Motor Article No. 03-20-1 10/13/03 ELECTRICAL - REAR WIPER ARM REMOVAL - SERVICE TIP FORD: 2001-2004 ESCAPE ISSUE Some Escape vehicles may exhibit the rear wiper arm being seized to the motor and difficult to remove. This may be caused by an insufficient amount of anti-seize compound on the arm/motor shaft splines. ACTION For vehicle service requiring the removal of the rear wiper arm, the following Service Procedure will help to free the wiper arm from the motor shaft. NOTE DO NOT ATTEMPT TO REMOVE THE WIPER ARM BY CUTTING THE MOTOR SHAFT WITH A HACKSAW OR GRIND TOOL. CUTTING THE MOTOR SHAFT WILL MAKE THE MOTOR UNUSABLE REQUIRING REPLACEMENT. IN ADDITION, DAMAGE TO THE LIFTGATE GLASS MAY OCCUR. HOWEVER IF THE REASON FOR SERVICE IS DUE TO AN INOPERABLE REAR WIPER MOTOR AND THE WIPER ARM IS SEIZED, THEN CUTTING THE MOTOR SHAFT IS AN ACCEPTABLE MEANS OF REMOVAL. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. SERVICE PROCEDURE 1. Confirm that wiper arm is seized on motor and that the wiper arm retainer latch is in the "release" position. 2. Mark and LIGHTLY center punch the exact center of arm mount "circle" (area over motor shaft). 3. Carefully drill through wiper arm using 1/8" drill bit. Do not drill into the motor shaft. NOTE PREVENT METAL SHAVINGS FROM FALLING ONTO THE BODY OR PAINT AS DAMAGE MAY OCCUR. 4. Enlarge the drilled hole using 3/8" drill bit. 5. Apply a small amount of penetrating oil at contact area of splines for wiper arm and motor. 6. Tap on joint area lightly to create vibration and facilitate penetrating oil working into splines of arm and motor. 7. Allow the oil to sit and penetrate for several minutes. NOTE BE SURE THE WIPER ARM RETAINER CLIP IS IN THE "RELEASE" POSITION BEFORE CONTINUING WITH STEP 8. 8. Install a puller with a 5/16" or smaller center screw (e.g. Battery Clamp Puller) to the wiper arm so that jaws of puller are pulling against the arm, and center post of puller is pressing against center of wiper motor shaft. NOTE ENSURE THAT JAWS OF PULLER ARE PULLING AGAINST WIPER ARM AND NOT MOTOR SHAFT BUSHING. 9. Tighten puller in very small increments while tapping lightly on the wiper arm and center shaft of puller. With pressure applied to the wiper arm and shaft a light shock should pop arm off of motor shaft. NOTE BE CAREFUL THAT ARM & PULLER DO NOT FALL AND DAMAGE THE LIFTGATE AND/OR BUMPER. 10. When installing the new wiper arm, remove all corrosion/rust from motor splines and apply anti-seize compound to splines of arm and motor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 03-20-1 > Oct > 03 > Wipers/Washers - Rear Wiper Arm Seized to Motor > Page 8539 NOTE IF AFTER PERFORMING THIS PROCEDURE THE WIPER ARM STILL CANNOT BE REMOVED, THEN CAREFULLY CUT MOTOR SHAFT AND REPLACE MOTOR AND WIPER ARM. USE CAUTION AS TO NOT DAMAGE THE VEHICLE'S PAINT, GLASS, BODY PANELS, ETC. INSTALL PROTECTIVE TAPE AND/OR AN PROTECTIVE COVERING AROUND THE LIFTGATE AREA AND BELOW REAR WIPER MOTOR. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Wiper Motor: Connector Views Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8542 Wiper Motor: Testing and Inspection WINDSHIELD WIPER MOTOR Use an Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor; refer to Wiper Pivot Arm-Front or Wiper Pivot Arm-Rear. Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal (terminal 3). Test the low-speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low-speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, install a new windshield wiper motor. Test the high-speed mode by connecting a cable from the battery positive (+) post to the (7) high-speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, install a new wiper motor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor WINDSHIELD WIPER MOTOR REMOVAL 1. Remove the cowl top vent panels. 2. Remove the wiper mounting arm and pivot shaft. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the wiper mounting arm and pivot shaft. 3. Remove the windshield wiper motor. 1 Remove the bolt and windshield wiper motor linkage. 2 Remove the windshield wiper motor mounting bolts. 3 Remove the windshield wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 8545 Wiper Motor: Service and Repair Rear Window Wiper Motor REAR WINDOW WIPER MOTOR REMOVAL 1. Remove the pivot arm. 1 Lift pivot arm to the upright position. 2 Slide the locking tab out. 3 Pull up and remove the pivot arm. 2. Remove the rear wiper motor shaft nut cover. 3. Remove the rear wiper motor shaft nut. 4. Open the liftgate. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 8546 5. Remove the rear wiper motor plastic cover. 6. Remove rear wiper motor. 1 Disconnect the electrical connector. 2 Remove the nut. 3 Remove the bolt. 4 Remove the rear wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair WIPER MOUNTING ARM AND PIVOT SHAFT REMOVAL AND INSTALLATION 1. Refer to Wiper Motor. Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-20 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8553 Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8554 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Escape 2wd Workshop Manual (L4-122 2.0L DOHC VIN B Zetec SFI (2003)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8555